H70 80da en 001

Rough Terrain Forklift Trucks H70/80 DA
Operation and Maintenance Manual H70/80 DA

Page 2 de 90
Rough Terrain Forklift Trucks MAST EXPLORER

Page 4 of 90
INTRODUCTION
This manual has been written by staff at MECANO

CONTINENTAL S.A. in order to provide all the
necessary information for correct operation of the forklift
IMPORTANT
and to ensure correct and safe maintenance. Safety and
troubleshooting sections are also included. Due to continually improving our forklift models
and in order to improve our products further, there
may be slight differences between your model and
WARNING the model described in this manual.
In this case, contact the MECANO CONTINENTAL

S.A. Technical Support department for possible
Carefully read and understand this manual before clarifications or updates.
starting, operating and maintaining the machine.
This manual is divided into the following sections:
A) GENERAL INFORMATION
B) OPERATION AND OPERATING

INSTRUCTIONS
C) MAINTENANCE
D) SAFETY
E) TROUBLESHOOTING
F) APPENDICES
Section A: general information on the machine and its

main components. Serial number and technical details.
Section B: important for machine operators. All the

different controls and switches are described in this
section.
Section C: important for maintenance staff. This section

contains detailed information about the maintenance
program and the actions required during each
maintenance period.
Section D: important for all staff: operators,

maintenance and safety managers.
Section E: its purpose is to diagnose and solve

possible breakdowns (mast, brakes, engine, hydraulics,
etc.).
Section F: additional information such as hydraulic

schemes, load diagrams, etc.
These sections are in turn sub-divided into sequentially

numbered chapters and paragraphs to make it easier to
find information. The quickest way to find information is
to use the table of contents page.
If you have any trouble understanding this manual, or

parts of the manual, we recommend contacting the
Mecano Continental S.A. Technical Support department
or the after-sales department.

Page 5 of 90
SYMBOLS USED
While operating the forklift, the operator may find

himself in situations that require him to consult the
considerations and clarifications given in this manual.
IMPORTANT
In this manual, when such situations put the operator's Makes you aware of important technical
safety and the safety of others at risk and affect the information or practical advice that can help you
forklift's efficiency and its correct operation, specific operate the forklift more efficiently and safely.
instructions displaying a SPECIAL SYMBOL to highlight
such situations are given to minimise risks.
There are five special (or safety) symbols used in the

manual and these are always accompanied by other
ENVIRONMENTAL
key words that classify the situations according to the
potential hazard. PROTECTION
Each symbol is accompanied by text describing the
likelihood of a situation, what to look out for and the Makes you aware of important environmental
recommended method or behaviour to be adopted. protection information.
When necessary, this text includes prohibitions or
appropriate instructions to avoid risks.
In some cases the text may be accompanied by

illustrations.
The special (or safety) symbols are shown below in

order of importance:
HAZARD
Warns you of situations that endanger your safety
and the safety of others with risks of serious harm
to personnel or the forklift, which may even result
in death.
ELECTRICAL
HAZARD
and the safety of others with serious electrical
hazards, which may even result in death.
WARNING
and the safety of others with risks of minor
accidents or injury, or that risk compromising the
forklift's efficiency.

Page 6 of 90
TABLE OF CONTENTS
A) GENERAL INFORMATION
B) OPERATION AND OPERATING

INSTRUCTIONS
C) MAINTENANCE
D) SAFETY
E) TROUBLESHOOTING
F) APPENDICES

Page 7 of 90
CONTENTS:
SECTION A: GENERAL INFORMATION

A-1 CONVENTIONAL REFERENCES ........................................................................................................................ 12
A-1.1 Information on the forklift (instruction stickers) .............................................................................................. 12
A-1.2 Forklift layout .................................................................................................................................................. 13
A-2 FORKLIFT INFORMATION .................................................................................................................................. 14

A-2.1 Manufacturer .................................................................................................................................................. 14
A-2.2 Model and type. Chassis number .................................................................................................................. 14
A-2.3 Permissible loads per model .......................................................................................................................... 15
A-2.4 Main measurements and specifications ......................................................................................................... 16
A-2.5 Engine specifications ..................................................................................................................................... 17
A-2.6 Fluids .............................................................................................................................................................. 17
A-2.7 Wheels and brakes ........................................................................................................................................ 17
A-2.8 Other data of interest ..................................................................................................................................... 18
A-2.9 Forklift's residual capacity .............................................................................................................................. 18
A-3 PERMITTED USES .............................................................................................................................................. 18

A-4 IMPROPER USE .................................................................................................................................................. 18
SECTION B: OPERATION AND OPERATING INSTRUCTIONS

B-1 BEFORE CLIMBING INTO THE FORKLIFT ........................................................................................................ 22
B-2 CLIMBING INTO THE FORKLIFT ........................................................................................................................ 22
B-2.1 Entering the cabin .......................................................................................................................................... 22
B-2.2 Adjusting the seat........................................................................................................................................... 23
B-2.3 Putting on the seat belt .................................................................................................................................. 23
B-2.4 Adjusting the steering wheel .......................................................................................................................... 23
B-2.5 Adjusting the rear-view mirrors ...................................................................................................................... 24
B-3 OPERATOR'S CONTROL PANEL ....................................................................................................................... 24

B-3.1 Key positions .................................................................................................................................................. 24
B-3.2 Instruments and controls ................................................................................................................................ 24
B-3.3 Joystick .......................................................................................................................................................... 26
B-3.4 Hydraulic oil level gauges .............................................................................................................................. 27
B-3.5 Lights panel and hour meter .......................................................................................................................... 27
B-4 ELECTRICAL SYSTEM ........................................................................................................................................ 28

B-5 STARTING ............................................................................................................................................................ 29
B-5.1 Starting using external power source............................................................................................................. 29

Page 8 of 90
B-5.2 Disconnecting the battery .............................................................................................................................. 29
B-5.3 Battery location .............................................................................................................................................. 29
B-5.4 Battery disposal .............................................................................................................................................. 29
B-6 TRANSPORTING THE FORKLIFT ...................................................................................................................... 30

B-6.1 Transporting and towing the broken-down forklift .......................................................................................... 30
B-6.2 Transporting by crane .................................................................................................................................... 30
B-7 CLEANING AND WASHING THE FORKLIFT ...................................................................................................... 30

B-7.1 Disposal. End of service life ........................................................................................................................... 30
SECCIÓN C: MAINTENANCE
C-1 HEALTH AND SAFETY STANDARDS ................................................................................................................ 32
C-2 SCHEDULED FORKLIFT MAINTENANCE.......................................................................................................... 32
C-3 MAINTENANCE ON THE PERKINS 1104D-44T ENGINE .................................................................................. 35
C-3.1 Main engine components ............................................................................................................................... 35
C-3.2 Engine identification ....................................................................................................................................... 35
C-3.3 Inspection of the engine alternator ................................................................................................................ 36
C-3.4 Inspection of the alternator belt ..................................................................................................................... 36
C-3.5 Instructions for replacing the belt: .................................................................................................................. 36
C-3.6 Changing the coolant ..................................................................................................................................... 37
C-3.7 Checking the coolant level ............................................................................................................................. 38
C-3.8 Replacing the air filter .................................................................................................................................... 38
C-3.9 Cleaning the air filter ...................................................................................................................................... 39
C-3.10 Engine oil level. ............................................................................................................................................ 40
C-3.11 Changing the engine lubricating oil.............................................................................................................. 40
C-3.12 Changing the engine oil filter ....................................................................................................................... 40
C-3.13 Fuel injectors ................................................................................................................................................ 41
C-3.14 Priming the fuel system................................................................................................................................ 41
C-3.15 Changing the primary fuel filter .................................................................................................................... 42
C-3.16 Changing the secondary fuel filter ............................................................................................................... 43
C-4 HYDROSTATIC SYSTEM MAINTENANCE......................................................................................................... 43

C-4.1 Changing the hydrostatic pump's hydraulic oil filter....................................................................................... 44
C-4.2 Maintaining the hydrostatic pump .................................................................................................................. 44
C-4.3 Hydrostatic regulation and pressure measurement ....................................................................................... 46
C-4.4 Releasing the hydrostatic pump for towing the forklift ................................................................................... 46
C-5 ELECTRICAL SYSTEM MAINTENANCE ............................................................................................................ 47

Page 9 of 90
C-5.1 Battery ............................................................................................................................................................ 47
C-5.2 Fuses and relays ............................................................................................................................................ 48
C-6 TRANSMISSION SYSTEM MAINTENANCE. GREASING THE FORKLIFT ....................................................... 48

C-7 FORK CHECK ...................................................................................................................................................... 49
C-8 MAST MAINTENANCE AND GREASING............................................................................................................ 49
C-9 TYRE PRESSURE ............................................................................................................................................... 51
C-10 TIGHTENING OF WHEEL BOLTS ..................................................................................................................... 52
C-11 TECHNICAL SPECIFICATIONS OF FORKLIFT FLUIDS .................................................................................. 52
C-12 MAINTENANCE PROGRAMME FOR THE PERKINS 1104D-44T SERIES ENGINE ...................................... 53
SECTION D: SAFETY
D-1 GENERAL OBSERVATIONS ............................................................................................................................... 56
D-2 CONDITIONS TO BE MET BY OPERATORS ..................................................................................................... 56
D-3 RESIDUAL RISKS ................................................................................................................................................ 56
D-4 NOISE EMISSIONS AND VIBRATIONS .............................................................................................................. 56
D-5 DESCRIPTION AND SAFETY DEVICES ............................................................................................................ 57
D-6 SAFETY RECOMMENDATIONS ......................................................................................................................... 58
D-7 RULES ON DRIVING THE FORKLIFT ................................................................................................................ 59
D-8 AT THE END OF THE DAY.................................................................................................................................. 60
D-9 GENERAL SAFETY MEASURES REGARDING THE ENGINE .......................................................................... 60
D-10 GENERAL SAFETY MEASURES REGARDING THE ELECTRICAL SYSTEM................................................ 62
D-11 PERSONAL PROTECTION ............................................................................................................................... 62
SECTION E: TROUBLESHOOTING
E-1 MALFUNCTION AND FAULT FINDING ............................................................................................................... 66
E-2 PROBLEMS - CAUSES- SOLUTIONS ................................................................................................................. 66
E-2.1 Movements ..................................................................................................................................................... 66
E-2.2 Electrics .......................................................................................................................................................... 67
E-2.3 Brakes ............................................................................................................................................................ 67
E-2.4 Mast................................................................................................................................................................ 67
E-2.5 Engine ............................................................................................................................................................ 68
SECTION F: APPENDICES
F-1 HYDRAULIC DIAGRAM H70 (2WD) .................................................................................................................... 70
F-5 TIGHTENING TORQUES ..................................................................................................................................... 74
F-6 LOAD DIAGRAMS ................................................................................................................................................ 76
F-7 MAINTENANCE REPORT TEMPLATES ............................................................................................................. 77

Page 10 of 90
Section A
GENERAL INFORMATION
CONTENTS
A-1 CONVENTIONAL REFERENCES
A-1.1 Information on the forklift (information stickers)
A-1.2 Forklift layout
A-2 FORKLIFT INFORMATION
A-2.1 Manufacturer
A-2.2 Model and type. Chassis number
A-2.3 Permissible loads per model
A-2.4 Main measurements and specifications
A-2.5 Engine specifications
A-2.6 Fluids
A-2.7 Wheels and brakes
A-2.8 Other data of interest
A-2.9 Forklift's residual capacity
A-3 PERMITTED USES
A-4 IMPROPER USE

Page 11 of 90
A-1 CONVENTIONAL REFERENCES
A-1.1 Information on the forklift (instruction stickers)

There are several stickers on the forklifts that give safety and operating information. Carefully read the instruction
stickers before operating the forklift. The following photo shows the H70 DA 4WD model. The instruction stickers on
the H70 DA and H80 DA models are in the locations shown below:

Page 12 of 90
A-1.2 Forklift layout Main external components:

The following photo shows the layout of the forklift. This
is to ensure that any reference to the different parts of Number Description
the forklift (front, rear, etc.) in this manual is clear in
1 FRONT DRIVE AXLE
order to avoid errors in terms of name and position.
2 REAR AXLE
3 COUNTERWEIGHT
TOP 4 ENGINE
5 REAR LIGHTS AND INDICATORS
6 STEERING WHEEL
7 OVERHEAD GUARD
8 MAST
LEFT SIDE FRONT 9 CARRIAGE
10 SEAT
11 CHASSIS NUMBER
12 FUEL TANK
RIGHT SIDE
REAR
BOTTOM
7
8
6
9 4
10 11 2
12

Page 13 of 90
A-2 FORKLIFT INFORMATION A-2.1 Manufacturer

The forklift truck manufacturer is MECANO
CONTINENTAL, S.A. This company has developed
IMPORTANT various models of H70/80DA rough terrain forklift

trucks with different capacities and specifications. Each
forklift truck will be identified by a serial number
recorded on the CE mark data plate attached to the
Check that you have the right operation manual. If forklift since Mecano Continental S.A meets the
you need further information or technical support,
requirements set out in Directive 2006/42/EC on the
you must specify the model and type of forklift
harmonisation of the laws of Member states relating to
plus the chassis number.
machinery.
Forklift information can be found on the data plate fitted

in the cabin, similar to the one shown below.
This data plate gives the following information:

• Make
• Model
• Load capacity
• Lift height
• Centre of gravity
• Weight
• Serial No.
• Year of manufacture
• CE mark
• Engine rating A-2.2 Model and type. Chassis number
• Tyre pressure To correctly identify the forklift model and type, Mecano
Continental S.A has engraved a number on the front
right-hand side of the chassis forklift behind the mast,
as shown in the following photo.
The different available configurations of the MAST

EXPLORER H70/80DA range are:
2WD (2 wheel drive):
H70DA, H80DA
4WD (4 wheel drive):
H70DA, H80DA

Page 14 of 90
A H70/80DA rough terrain forklift truck can be

described as a self-propelled machine that has a mast
with a determined rated load capacity for lifting loads
using forks. Load capacities are given below according
HAZARD
to the mast model fitted:
The following diagrams are valid for a lift height of
3300, 4300 and 6000 mm (without additional
RATED CAPACITY OF THE MAST attachments fitted).
H70 DA (7,000 kg) M
H80 DA (8,000 kg)
Load diagrams for the H70DA and H80DA models are
N
shown below. The load is given in kg on the vertical
axis and the distance from the centre of gravity (CG) to
The MAST EXPLORER H70/80DA rough terrain forklift the carriage is given in mm along the horizontal axis,
trucks have been designed to carry and lift loads with CG being 500 mm for the standard load.
vertically. The forklift truck is a self-contained vehicle
suitable for carrying hanging loads and is designed for
such use. FOR H70 DA MODEL: Mast height 3300 mm
Mast height 4300 mm
Load (kg) Mast height 6000 mm
FORKLIFT INFORMATION:
To be able to understand the model's code we must

understand the following:
CG_Qe (mm)
FOR H80 DA MODEL: Mast height 3300 mm

Mast height 4300 mm
Load (kg) Mast height 6000 mm
CG_Qe (mm)
For greater heights, the loss of capacity charts adhered

to the forklift truck will be used to ensure that the
operator uses the forklift truck safely.
A-2.3 Permissible loads per model
The loss of capacity charts are similar to the one shown
The maximum permissible load of each forklift will vary below and are adhered to the forklift:
according to the forklift model and the mast fitted.

Page 15 of 90
MAIN MEASUREMENTS
TOTAL LENGTH (mm) L1 5725
LENGTH TO FORK CARRIAGE (mm) L2 4225
DISTANCE FROM LOAD TO FRONT
X1 825
AXLE (mm)
WHEEL BASE (mm) Y 2575
REAR OVERHANG (mm) X2 825
TOTAL WIDTH (mm) B 2245
TOTAL HEIGHT WITHOUT MAST (mm) H6 2450
FRONT/REAR TREAD (mm) (2WD) C1/C2 1830 / 1560
TOTAL HEIGHT WITH MAST (mm) H1 3050
IMPORTANT TOTAL HEIGHT WITH MAST EXTENDED

(mm)
GROUND CLEARANCE, MINIMUM
H4 7087
M1 320/300
2WD/4WD
The capacity loss charts shown here are for GROUND CLEARANCE, CENTRE OF
illustrative purposes only as only those charts that M2 370/350
WHEEL BASE 2WD/4WD
apply to a specific model are adhered to that TURNING RADIUS (mm) 2WD/4WD WA 4860/5350
forklift according to each model's rated
DRIVING SEAT HEIGHT (mm) H7 1415
specifications.
PERMISSIBLE WEIGHTS
A-2.4 Main measurements and specifications
SERVICE WEIGHT (kg) 9850
The forklifts' main weights and measurements are given GVWR / GVW (kg) 16850
below.
GVWR / GVW, FRONT (kg) 17200
GVWR / GVW, REAR (kg) 5700
IMPORTANT
The weights and measurements given below are W A
exclusively for the models indicated. Any
modification made to the forklift that may affect its
load capacity invalidates the original diagram.
FOR H70 DA MODELS (2WD and 4WD)

C1
C2
B
H1
H6
FOR H80 DA MODELS (2WD and 4WD)

H7
M1
M2
X1 Y X2
L L2
H1
L1
H6
H7
FORKLIFT WEIGHTS
TOTAL UNLADEN WEIGHT (kg) 9850
M1
M2
WEIGHT ON AXLES WITH LOAD (FRONT/REAR)

15650 / 1200
(kg) X1 Y X2
L L2
WEIGHT ON AXLES WITHOUT LOAD L1
4650 / 5200
(FRONT/REAR) (kg)
MAXIMUM PERMISSIBLE WEIGHT (kg) 16850

Page 16 of 90
FORKLIFT WEIGHTS FOR H70/H80 DA MODELS (2WD and 4WD)

TOTAL UNLADEN WEIGHT (kg) 10850
MAST
WEIGHT ON AXLES WITH LOAD (FRONT/REAR)
17420 / 1430 TYPE TRIPLEX
(kg)
WEIGHT ON AXLES WITHOUT LOAD MAXIMUM HEIGHT (mm) 6000
4725 / 6125
(FRONT/REAR) (kg) WEIGHT (kg) 2000
MAXIMUM PERMISSIBLE WEIGHT (kg) 18850 FORK LENGTH (L) (mm) 1500
TOTAL LIFT HEIGHT (H3) mm 6000
MAIN MEASUREMENTS
FREE LIFT (H2) mm 1963
TOTAL LENGTH (mm) L1 5725
LOAD CENTRE OF GRAVITY (CG) mm 600
LENGTH TO FORK CARRIAGE (mm) L2 4225
FORK CARRIAGE FEM IV B
DISTANCE FROM LOAD TO FRONT
X1 825 TILT FORWARD/BACKWARD º/º 10 / 12
AXLE (mm)
WHEEL BASE (mm) Y 2575 MAXIMUM LOAD LIFTING SPEED m/s 0.4
REAR OVERHANG (mm) X2 825 MAXIMUM LOAD LOWERING SPEED m/s 0.5
TOTAL WIDTH (mm) B 2245

A-2.5 Engine specifications
TOTAL HEIGHT WITHOUT MAST (mm) H6 2450
ENGINE
MAKE / MODEL Perkins / 1104D-44T
TOTAL HEIGHT WITH MAST (mm) H1 3050
NO. CYLINDERS / DISPLACEMENT 4 / 4400 cm3
TOTAL HEIGHT WITH MAST EXTENDED
H4 7087
(mm) ACTUAL OUTPUT HP / KW 100 / 74.5
GROUND CLEARANCE, MINIMUM RATED OUTPUT HP / KW 21.37 / 15.72
M1 320/300
2WD/4WD
GROUND CLEARANCE, CENTRE OF
M2 370/350 A-2.6 Fluids
WHEEL BASE 2WD/4WD
TURNING RADIUS (mm) 2WD/4WD WA 4860/5350
DRIVING SEAT HEIGHT (mm) H7 1415 FLUID CAPACITIES
ENGINE OIL (l) 11
HYDRAULIC SYSTEM (l) 160
PERMISSIBLE WEIGHTS
COOLING SYSTEM (l) 25
SERVICE WEIGHT (kg) 10850
FUEL (l) 140
GVWR / GVW (kg) 18850
GVWR / GVW, FRONT (kg) 20000
A-2.7 Wheels and brakes
GVWR / GVW, REAR (kg) 7500
RUEDAS Y FRENOS
FRONT WHEELS H70DA 16x70-16.5 14PR

REAR WHEELS H80DA 420/75 R20
W A
H70DA 400x60-15.5 14PR

SERVICE BRAKE
H80DA 280/80 R20
SERVICE BRAKE HYDRAULIC
H70DA MECHANIC DISC

C1
C2
B
PARKING BRAKE NEGATIVE –

H80DA ACTING
MULTIPLE - DISC

Page 17 of 90
A-2.8 Other data of interest A-3 PERMITTED USES

The MAST EXPLORER forklift trucks have been
OTHER DATA OF INTEREST designed and manufactured to lift, move and carry
TRAVEL SPEED WITHOUT LOAD 24 km/h
products. Any other use is not permitted and is therefore
considered improper use. Strict compliance with the
TRAVEL SPEED WITH LOAD 20 km/h operation, maintenance and repair conditions specified
RATED DRAWBAR PULL WITHOUT LOAD
4500 / 4100 daN
by Mecano Continental S.A is an essential element of
4WD/2WD permitted use.
GRADEABILITY WITHOUT LOAD 4WD/2WD 35 / 30 %
The forklift must only be used and maintained by people
GRADEABILITY WITH LOAD 4WD/2WD 30 / 25 % who are fully acquainted with its specifications and
FORWARD/REVERSE GEAR SHIFT ELECTRIC safety procedures. It is also necessary to respect all
accident prevention standards, generally recognised
DRIVE TYPE HYDROSTATIC occupational health and safety standards and all traffic
DRIVE OPERATING PRESSURE 420 bar standards.
AUXILIARY PRESSURE / FLOW
200 bar / 81 l/min
CONNECTION
BATTERY 12 V 110 AH 920 A WARNING

SOUND POWER LEVEL (PWL) < 104 dB (A)
HYDRSTATIC PUMP LINDE HPV 105 CA Any type of modification or change to the forklift,
except for modifications contemplated in this
A-2.9 Forklift's residual capacity manual for normal maintenance purposes, is
prohibited.
To improve safety when operating the forklift trucks, it is
recommended that the following formula be used if
loads with front dimensions greater than the standard A-4 IMPROPER USE
considered by Mecano Continental S.A., generally 1000
mm, are to be lifted (centre of gravity of 500mm): Using the MAST EXPLORER forklift trucks according to
operating criteria that do not comply with the
instructions contained in this manual and that could be
X= (S×N) / L dangerous for the operator or others is understood to be
improper use.
where:
X = residual capacity of the forklift with

bulky load
S = distance between the vertical axis of the front
HAZARD
wheels and the rated load centre (500 mm) Some of the most frequent and dangerous cases of
N= forklift's rated capacity improper use are listed below:
L = distance between the vertical axis of the front
wheels and the centre of gravity of to load to be − Transporting people on the forks
transported
− Not following the operation and
maintenance instructions given in this
WARNING −
manual to the letter
Exceeding mast, height and load limits
This formula is only valid in terms of lifting − Working on unstable pit/ditch edges
capacity. The stability and risks presented by the
vehicle when moving depend on many other − Travelling across slopes instead of up and
factors that are not taken into account in the down them
formula above.
− Working during heavy storms
− Working in excessively steep conditions as

there is a risk of overturning
− Using the equipment for Jobs other than for

which it was designed

Page 18 of 90
− Working in potentially explosive areas
− Working in enclosed or poorly ventilated

areas

Page 19 of 90

Page 20 of 90
Section B
OPERATION AND OPERATING
INSTRUCTIONS
CONTENTS
B-1 BEFORE CLIMBING INTO THE FORKLIFT
B-2 CLIMBING INTO THE FORKLIFT
B-2.1 Entering the cabin
B-2.2 Adjusting the seat
B-2.3 Putting on the seat belt
B-2.4 Adjusting the steering wheel
B-2.5 Adjusting the rear-view mirrors
B-3 OPERATOR'S CONTROL PANEL
B-3.1 Key positions
B-3.2 Instruments and controls
B-3.3 Joystick
B-3.4 Hydraulic oil level gauges
B-3.5 Lights panel and hour meter
B-4 ELECTRICAL SYSTEM
B-5 STARTING
B-5.1 Starting using external power source
B-5.2 Disconnecting the battery
B-5.3 Battery location
B-5.4 Battery disposal
B-6TRANSPORTING THE FORKLIFT
B-6.1 Transporting andTowing a broken-down forklift
B-6.2 Transporting by crane
B-7CLEANING AND WASHING THE FORKLIFT
B-7.1 Disposal. End of service life

Page 21 of 90
B-1 BEFORE CLIMBING INTO THE FORKLIFT Model Tyre Pressure

H70/H80
(2WD and Front 16x70-16.5 14PR 5 bar
WARNING 4WD)
H70/H80
(2WD and Front 420/75 R20 5 bar
4WD)
This section is support material for the operator H70/H80
that outlines how to operate the MAST EXPLORER Rear 400x60-15.5
(2WD and 4 bar
forklift truck. 14PR
4WD)
H70/H80
Once the operator has taken up his position inside the (2WD and Rear 280/80 R20 4 bar
operator's cabin and has completed the preliminary 4WD)
adjustment operations, he must then study and learn
the position of all the controls and instruments inside
the cabin.
B-2 CLIMBING INTO THE FORKLIFT
Becoming well acquainted with their position is vital to
B-2.1 Entering the cabin
ensure correct usage during operation and fast, timely
intervention by the operator should sudden manoeuvres Two steps or rungs plus a handhold on the cabin frame
become necessary to protect the safety of the operator are provided to make it easier to climb into the vehicle.
and the forklift.
IMPORTANT WARNING
Always make sure your hands and footwear are
Learn to operate the forklift and predict how it will dry and clean before climbing onto the step to
respond. Learn how to use the controls in an open, reach the driving seat. Always use the step to
safe space with no obstacles or people nearby. climb into or out of the cabin, holding onto the
Never jerk the controls; use them with caution special supports provided.
until you are sure what effect they have on the
forklift.
The forklift truck has been designed and manufactured
to be operated by an operator from the driving seat
Controlling and cleaning the forklift before starting: located at the front of the forklift in compliance with the
operating instructions given in this manual.
-Clean the windows, lights and rear-view mirrors.
-Check the wheel nuts, articulated machine parts
(mast) and overall condition of the forklift.
-Check for oil, fuel or coolant leaks
-Check the tyre pressure
-Check for possible cracks in covers
HAZARD
A burst tyre could cause serious injury. Do not
use the forklift with damaged, under-inflated or
worn tyres.
To check tyre wear and pressure, see the following

table: All the necessary components to drive the vehicle and
operate the vertical load lifting system are operated
from the driving seat.

Page 22 of 90
The operator should check the position of the

batterycut-off device. In a horizontal position, the
battery will be connected to the forklift's electrical
circuits and in a vertical position, the battery will be
disconnected from the forklift's electrical circuit.
B-2.2 Adjusting the seat

Careful seat adjustment ensures that the operator can
drive safely and comfortably. The seat has several
devices for regulating the seat's distance from the B-2.4 Adjusting the steering wheel
controls. For this purpose, the seat has a knob and
lever on the right-hand side. By using these devices, To adjust the steering wheel, use the adjusting handle
the seat can be adjusted to the desired position. on the left-hand side of the steering column as follows:
-Turn the handle anti-clockwise to loosen.
WARNING -Adjust the tilt of the steering wheel.

-Tighten the handle.
The operator should adjust the seat's distance in

order to be able to safely operate all of the
forklift's instruments and controls. HAZARD
Before driving, check that the steering wheel
adjusting handle is locked to prevent accidents.
To adjust the seat
WARNING
If you need to change the position of the handle,
pull the handle out, turn it towards the operator
and release in the appropriate position.
B-2.3 Putting on the seat belt
IMPORTANT
The operator should fasten his seat belt before
operating the forklift in any way. He should
periodically check the overall condition and
operation of the seat belt.
Sit correctly in the driving seat before doing the

following:
-The seat belts have retractors. To fasten the seat belts,

pull the tongue 1 and clip it into the buckle 2.
-To unfasten the seat belt, press the button 3 and

release the tongue from the buckle. Check that the seat
belt is positioned across the waist and not the stomach.
-Adjust the length of the seat belt at both ends, keeping

the buckle in the middle.

Page 23 of 90
B-2.5 Adjusting the rear-view mirrors

The forklift cabin is fitted with two exterior rear-view
mirrors attached to the overhead guard.
WARNING
Adjust the position of the rear-view mirrors by
rotating the mirror head by hand until you have a
clear view of the area behind the forklift.
HAZARD
B-3 OPERATOR'S CONTROL PANEL
After starting the engine, if you climb down from
BEFORE STARTING THE ENGINE the driving seat, the engine will still be running.
DO NOT LEAVE THE DRIVING SEAT WITHOUT
FIRST TURNING OFF THE ENGINE, LOWERING
WARNING THE MAST AND PUTTING THE PARKING BRAKE
ON!
To ensure the safety of the operator and others and B-3.2 Instruments and controls
a long machine service life, do an all-round check The forklift's main instruments and controls are
before starting the engine, as described below. described below:
-Remove all dirt from inside the cabin, particularly from

the area near the pedals and control levers.
-Remove all oil, grease or mud from the pedals and

control levers.
-Make sure your hands and footwear are clean and dry.
-Make sure the seat belt is secure.
-Check that the lights, gauges, indicators, emergency

lights and horn are in correct working order.
-Adjust the seat so you can comfortably reach all control

levers and fully depress the brake pedal with your back
still against the back of the driving seat.
-Adjust the rear-view mirrors so you have a good view

of the area behind the forklift while remaining seated
comfortably in the driving seat. WARNING
-Check that the parking brake is on.
The photo above shows a 2WD model with no
differential lock. On 4WD models, the differential
B-3.1 Key positions
lock button replaces the rear light switch.
To start the forklift, put the ignition key in the lock and
turn to operate. The key can be in the following
positions:
-Position 1: Off: The forklift is not running.

-Position 2: Heat: Engine preheating. Hold for 5
seconds and repeat the operation if the engine does not
start or if the outside temperature is very low.
-Position 3: On: The on position (the beacon comes
on).
-Position 4: Start: Starter.

Page 24 of 90
3 4 HAZARD
This brake must be activated with the forklift
stationary to prevent accidents.
5
Moving:
6 -If the parking brake is off:
2
8 1) To move forward: push the forward-reverse lever
7
1 forward and step on the accelerator to move the forklift
9 forward.
(The photo above shows the H70/80 DA 4WD model.
The position of the parking brake and differential
lock buttons can be seen on the image on the
previous page)
NUMBER DESCRIPTION
1 Steering column adjuster
2 Differential lock (4WD)
Forward-reverse lever and gear shift, 1st and

3
2nd gears
4 Parking brake
5 Indicators, headlights, horn
6 Key switch
7 Accelerator pedal
2) To reverse: Move the forward-reverse lever
backward and step on the accelerator. The reversing
8 Service brake pedal alarm will sound.
9 Hour meter
Gear shift:
Both the 2WD and 4WD high-end H70/80DA forklifts
Detailed description: have 2 gears. To change gear:
Indicators: move the lever to the right of the steering a) Turn the forward-reverse lever clockwise to
wheel up (left) or down (right) according to the direction select 1st gear (I).
of travel. b) Turn the forward-reverse lever anti-clockwise to
select 2nd gear (II).
Differential lock button: (4WD models only): To lock
the traction of all 4 wheels if one of the wheels loses
traction. Keep the button depressed until all 4
wheels regain traction. HAZARD
WARNING On putting the forklift into gear, the forklift can
move slowly even without stepping on the
accelerator.
On 4WD models, the forklift has permanent

traction to all 4 wheels. The differential lock 3) If the parking brake is on, the forklift will start but will
button must be used if one of the wheels loses not begin to move.
traction.
4) If the parking brake is off but the forklift is in gear, the
Parking brake switch forklift will not start.
Press to the right to activate.
5) The parking brake can be activated if the forklift is not
in gear (in neutral).

Page 25 of 90
To travel downhill with a load, drive with the rear of the
HAZARD forklift downhill while accelerating to control the

descent speed.
On operating the negative brake, the wheel motors lock

If the forklift is in gear and the button is pressed, and the forklift becomes completely immobilised.
the brake does not work.
Light switch:
-Position 0: lights off

WARNING
-Position 1: side lights and lights panel on
-Position 2: headlights on On this model, the parking brake is a negative
-Button 3: windscreen wiper brake on both the 2WD and the 4WD models. This
-Button 4: horn brake is activated using the emergency stop
button or when the corresponding button is
pressed.
B-3.3 Joystick
H70/80 DA joystick
B
C
D
A
Horn: Located on the end of the light switch. To
sound the horn, simply press the button.
Movements of the H70/80 DA joystick:
For the pedals:
-Forward: tilts the mast forward
-Backward: tilts the mast backward
-Left: lifts the mast
-Right: lowers the mast
2 Movements of the H70/80 DA side-shifter:

1
-Button A: shifts the mast carriage to the left
-Button B: shifts the mast carriage to the right
1) Service and emergency brake pedal -Rocker switch C: optional for 4th valve
(left pedal)
-Button D: hydraulic brake
2) Accelerator pedal (right pedal)

Page 26 of 90
WARNING 1) Hydraulic oil level window on the service tank

(mast and steering).
2) Hydraulic oil level window on the hydrostatic
transmission tank.
Before moving the forks, make sure nobody is
within the forklift's operating radius
Diagram of reversed function option

The client may ask for a joystick with the functions in a
HAZARD
different order.
If the oil level is not high enough, the tank should
be topped up with then oil specified in the
maintenance section.
HAZARD
If the hydraulic oil temperature exceeds 100ºC,
contact the Mecano Continental S.A. after-sales
department or qualified staff to check.
B-3.5 Lights panel and hour meter

The MAST EXPLORER forklift trucks have an hour
meter that also shows other information as described
below:
WARNING
For this option, the forklift's movements will be
ordered as indicated in the diagram above.
B-3.4 Hydraulic oil level gauges

The forklift has 2 gauges or indicators to warn the
operator as shown below:

Page 27 of 90
NUMBER DESCRIPTION FUSE No. NAME AMPERAGE (A)
1 Hour meter 17 Service brake 10
2 Side lights 18 Forward drive 5
3 Air filter change 19 Reverse 5
20 Heating 25
4 Transmission filter change
21 General fuse (large) 50
5 Engine oil pressure
6 Battery charge
7 Preheating
8 Engine water temperature
9 Indicators
10 Headlights
11 Fuel level
B-4 ELECTRICAL SYSTEM

Electric power is provided by a maintenance-free, DC
battery located beneath the driving seat as follows: 12
volt, 110 AH and 970 A for the H70/80 DA range.
ELECTRICAL
HAZARD
Specifications of the electrical system are given below:
-The fuse box, which is shown in the photo below, is

located next to the engine on the rear left-hand side of
the forklift.
-A numbered chart is located behind the fuse box cover

to indicate the position of each fuse or relay. The fuses
WARNING
fitted in the forklifts are shown in the following table:
Only use fuses with the indicated amperage.
FUSE No. NAME AMPERAGE (A) Failure to do so could lead to damage to or fire in
the printed circuit board.
1 Rotating beacon 15
2 Windscreen wiper 25
The fuse box is accessed by lifting the bonnet located
3 Hour meter 5 at the rear of the forklift. It should be accessed in
4 Forward-reverse lever 10 accordance with the instructions given in the
5 Full-beam headlights 15 maintenance section of this manual.
The electrical installation must comply with Royal
6 Dipped headlights 15
Decree 1580/2006, transposing the 2004/108/EC
7 Right rear light 7.5 directive on Electromagnetic Compatibility, and the
8 Left rear light 7.5 UNE-EN 1175 regulation on safety of industrial trucks.
9 Indicators 10
10 Horn 10
11 Engine heater 30
12 Battery level indicator 7.5
13 Gear stick 10
14 Fuel level 15
15 Work light 15
16 Negative brake 15

Page 28 of 90
B-5 STARTING
B-5.1 Starting using external power source
HAZARD
When jump starting from another battery that is -Connect the two batteries by first connecting the
not part of the forklift, avoid contact between the positive terminals (+) and then the negative terminals
cable clamps once connected to the battery to using the clamps provided for this purpose.
prevent sparks.
-Proceed to start the forklift's engine using the start
switch.
-Disconnect the cables by first removing the negative

cable (-) from the earthing point and then from the
HAZARD auxiliary battery.
-Disconnect the positive cable (+) from the forklift's

Batteries produce a flammable gas that could be battery and then from the auxiliary battery.
ignited by the sparks, causing the battery to
explode. Do not smoke when checking the
electrolyte. HAZARD
Only use a 12V battery as other devices (battery
chargers, etc.) could cause the battery to explode
ELECTRICAL or damage the electrical installation.
HAZARD B-5.2 Disconnecting the battery

If any type of repair or maintenance work is required on
Keep the positive cable (+) from the battery away the forklift, particularly work involving welding, it is
from any metal object, such as buckles, watch necessary to turn off the general battery switch located
straps, etc., that could cause a short circuit beneath the seat on the left-hand side.
between the battery terminal and nearby metal,
resulting in the risk of burns for the operator. B-5.3 Battery location
The MAST EXPLORER forklift truck battery is located
beneath the foot rest, inside the cabin. To access the
battery, the foot rest must be removed.
IMPORTANT B-5.4 Battery disposal
The battery used for jump starting must have the

same voltage (12V) and capacity as the battery
fitted in the forklift.
ENVIRONMENTAL
PROTECTION
To start the engine using a external battery, proceed as
explained below:
The lead-acid batteries used cannot be disposed
-Disconnect the forklift battery using the cut-off device of with regular industrial solid waste; instead they
fitted must be collected, disposed of and/or recycled
according to the laws of the country where the
forklift is located.

Page 29 of 90
B-6 TRANSPORTING THE FORKLIFT B-7 CLEANING AND WASHING THE FORKLIFT
To clean the forklift correctly, follow these instructions:
B-6.1 Transporting and towing the broken-down
forklift
-Clean dirty areas affected by oil or grease using dry
If the forklift breaks down and needs to be transported, solvents or volatile mineral alcohol.
take the following into account:
-Before assembling new spare parts, remove all
-The load capacity (permissible load) of the transport protective material (anti-rust, grease, wax, etc.)
vehicle must be greater than the weight of the forklift.
-If there are signs of rust on metal parts of the forklift,
-Keep a safe distance from edges, ramps, work clean using sandpaper and cover with adequate
platforms, etc. protection (anti-rust, varnish, oil, etc.).
-Completely lower the forks Exterior washing
Before washing, check that the engine is off and that

-Put the parking brake on. Remove the key
doors and windows are closed. Do not use fuel for
cleaning; use only water or a steam jet. In cold climates,
-Put 2 chocks in front of and behind front and rear
dry locks after washing or moisten with antifreeze.
wheels to prevent movement Before using the forklift, reset all pre-wash conditions.
-Secure with ropes and tighten Interior washing
Wash the interior of the forklift using water and a

WARNING sponge. Never use pressurised water. After washing,
dry with a clean cloth.
Engine washing
For the MAST EXPLORER model, the forklift may
only be towed if the instructions given in the Wash the engine after applying water-proofing to the
maintenance section of this manual are complied air intake filter located on top of the engine bonnet as
with. water can get into the engine via the air filter.
B-7.1 Disposal. End of service life

B-6.2 Transporting by crane
Loading by crane is only considered for the initial
transportation of the forklift when commissioned. If
frequent loading of the forklift by crane is required at
ENVIRONMENTAL
the work site, consult Mecano Continental S.A. PROTECTION
HAZARD At the end of the forklift's service life, we
recommend not leaving the forklift discarded as
waste but rather to contract specialised companies
Only people with adequate experience using the to dispose of the forklift in compliance with current
appropriate securing and lifting devices may load regulations.
the forklift for transportation.
IMPORTANT
To lift the forklift, use loading devices and tackle
that have sufficient load capacity.
Textile devices may be used to protect edges. Secure

the forklift using the bolt attached to the forklift's rear
counterbalance and the mast at the front.

Page 30 of 90
Section C
MAINTENANCE
CONTENTS
C-1 HEALTH AND SAFETY STANDARDS C-4 HYDROSTATIC SYSTEM MAINTENANCE
C-2 SCHEDULED FORKLIFT MAINTENANCE C-4.1 Changing the hydrostatic pump's

hydraulic oil filter
C-3 MAINTENANCE ON THE PERKINS 1104D-
44T ENGINE C-4.2 Maintaining the hydrostatic pump
C-3.1 Main engine components C-4.3 Hydrostatic regulation and pressure

measurement
C-3.2 Engine identification
C-4.4 Releasing the hydrostatic pump for towing
C-3.3 Inspection of the engine alternator the forklift
C-3.4 Inspection of the alternator belt C-5 ELECTRICAL SYSTEM MAINTENANCE
C-3.5 Instructions for replacing the belt C-5.1 Battery
C-3.6 Changing the coolant C-5.2 Fuses and relays
C-3.7 Checking the coolant level C-6 TRANSMISSION SYSTEM MAINTENANCE.

GREASING THE FORKLIFT
C-3.8 Replacing the air filter
C-7 FORK CHECK
C-3.9 Cleaning the air filter
C-8 MAST MAINTENANCE AND GREASING
C-3.10 Engine oil level
C-9 TYRE PRESSURE
C-3.11 Changing the engine lubricating oil
C-10 TIGHTENING OF WHEEL BOLTS
C-3.12 Changing the engine oil filter
C-11 TECHNICAL SPECIFICATIONS OF
C-3.13 Fuel injectors FORKLIFT FLUIDS
C-3.14 Priming the fuel system C-12 MAINTENANCE PROGRAMME FOR THE
PERKINS 1104D-44T ENGINE
C-3.15 Changing the primary fuel filter
C-3.16 Changing the secondary fuel filter

Page 31 of 90
INTRODUCTION Storage
Always store oils in a sealed place out of the reach of
Regular, correct maintenance will give the operator a children. Never leave lubricant containers open and
forklift that is always safe and operational. For this without a label indicating their content to avoid
reason, after having worked in particularly adverse mistakes.
conditions (muddy, dusty terrain, heavy work, etc.),
washing, greasing and correct maintenance of the Disposal
forklift is recommended. Disposing of new or used oil is highly contaminating for
the environment.
Always check that all forklift components are in good Carefully store new oil and keep used oil in special
working condition, there are no oil leaks and safety containers for subsequent disposal by specific waste
guards and devices are efficient. If this is not the case, disposal centres.
find and resolve the causes.
Spillage
In the event of accidental oil spills, use sand or a
WARNING suitable granulate to soak up the oil. Scrape off the

compound obtained and dispose of as chemical waste.
Emergencies
Mecano Continental S.A. recommends using
ORIGINAL MAST EXPLORER SPARE PARTS to -Eyes: If oil comes into contact with the eyes, rinse with
ensure adequate operation of the forklift. copious amounts of running water. If irritation continues,
go to the nearest hospital.
-Ingestion: If oil is ingested, do not induce vomiting. See

a doctor.
-Skin: In cases of excessive and prolonged contact with

Maintenance operations are scheduled according to the the skin, wash with soap and water.
number of service hours completed by the forklift. Keep
track of service hours to be able to correctly determine -Fire: In the event of a fire, use CO2, dry powder or
maintenance intervals. For this purpose an hour meter foam fire extinguishers. Do not use water.
is fitted on the steering column.
C-2 SCHEDULED FORKLIFT MAINTENANCE
Non-compliance with the scheduled maintenance

standards indicated in this manual automatically cancels
IMPORTANT
the guarantee given by Mecano Continental S.A.
Incorrect maintenance or no maintenance at all
maymake the forklift dangerous for the operator
IMPORTANT and others in the surrounding area.
Make sure maintenance and lubrication are done

For engine maintenance, carefully follow the regularly as indicated by Mecano Continental S.A in
specific operation and maintenance manual this manual in order to keep the forklift safe and
supplied by Mecano Continental S.A with the operational. Maintenance operations are scheduled
forklift. according to the number of service hours completed by
the forklift.
Keep track of service hours to be able to correctly

C-1 HEALTH AND SAFETY STANDARDS determine maintenance intervals using the hour meter
Health fitted on the steering column.
Prolonged contact of oils with the skin may cause
irritation. Therefore rubber gloves and goggles are
recommended. After handling oils, thoroughly wash
your hands with soap and water.

Page 32 of 90
engine and the filter and check that it is in good

WARNING condition
After 250 service hours or monthly
All operations marked by the following symbol Grease roller bearings, bushings and articulations
must be done by a specialized technician. Grease lifting chains and mast guides
Check for correct operation of the lifting cylinders
Within the first 10 service hours
Check the condition of the engine's air filter cartridge;
Check the engine oil and fuel levels replace if necessary
Check the hydraulic oil level in the tank Check the battery fluid level
Frequently check the wheel bolt tightening torque Check that the terminals are tightly fastened to the
battery posts
Check the torque of all screws/bolts
Check that the hydraulic tubes are not worn as a result
Check for possible oil leaks from the hydraulic
of rubbing against the chassis or other mechanical
connections
components
Check the coolant level in the radiator
Check for wear to the rollers
Clean the engine radiator on the mast sections
Check parking brake operation Check the battery fluid level
Check the cleanliness of the hydraulic tank breather Inspect forks and mast
and check that it is not blocked
Every 500 service hours
Check the tyre pressure
Operations to be carried out in addition to others
Within the first 50 service hours mentioned above
Change the engine oil for the first time Visually check the amount of fumes from the
exhaust pipe
Change the hydrostatic pump's hydraulic oil filter
Check that the bolts attaching the engine to the silent
Every 10 service hours or daily blocks are tight
Check the engine oil level Check that there is no excessive play between
Clean the air intake filter bolts and bushings at all joints
Clean the radiator, if necessary Change hydraulic oil filter
Check the hydraulic oil level in the tank Check brake linings or disc brake pads
Check that the components of the mast Change engine oil filter, air filter and fuel filter
sections are well greased to ensure that rollers slide Change the engine oil
along rails
Check for correct operation of the hydrostatic pump
Check for correct operation of the electrical
lighting installation Check mast bushings
Check for correct operation of the brake Grease mast support bolts
system and parking brake
Every 1000 service hours or every year
Check that the steering system is working properly
Check the brake discs and parking brake
Check for correct operation of the service brake
Grease the wheel hubs and bearings
Every 50 service hours or weekly
Change brake fluid
Operations to be carried out in addition to daily
operations Change hydraulic oil
Check the alternator belt tension Change coolant
Check the tyre pressure Check front differential carrier oil level
Check the wheel bolt tightening torque Check front differential assembly oil level
Check the friction of the air intake tube between the Check rear wheel motor oil level

Page 33 of 90
After each repair affecting the hydraulic system

Change oil and hydraulic filters WARNING
Before working on the hydraulic lines or
components, make sure there is no pressure in
WARNING the system. To do this, after turning off the engine
and putting the parking brake on, move the
distributor control levers (in the opposite direction
These service hours / intervals are to the operating direction) to release pressure
recommendations when operating the from the hydraulic circuit.
forklift under normal conditions.
Depending on usage and work
environment, these intervals may be
longer or shorter.
IMPORTANT
The high-pressure lines may only be replaced by
IMPORTANT qualified staff. Any impurity in the closed circuit
rapidly deteriorates the transmission and
hydrostatic pump.
It is vital that these maintenance intervals be
followed in order to claim a repair under the
guarantee.
IMPORTANT
HAZARD The qualified staff performing maintenance on the
hydraulic circuit must carefully clean the
surrounding areas before carrying out any
All maintenance work must be carried out with the operation.
engine stopped, the parking brake on and the mast
resting on a flat surface on the ground.
ENVIRONMENTAL
PROTECTION
WARNING
Used oils should be handled and disposed of in
Before any maintenance operation involving the compliance with national standards and
lifting of a component, secure the component to regulations. Make sure there are authorised
be lifted to keep it safe and steady prior to moving. disposal sites.
WARNING
Operations on the hydraulic system are strictly
prohibited unless carried out by authorised staff.
This forklift's hydraulic installation has high-
pressure connections and lines that could cause
serious personal injury if not disconnected prior
to carrying out maintenance on the system.

Page 34 of 90
C-3 MAINTENANCE ON THE PERKINS 1104D-44T Number

ENGINE 13 Flywheel
14 Flywheel housing
C-3.1 Main engine components 15 Fill tube cap
16 Exhaust manifold
17 Turbo-compressor
18 Oil dipstick
19 Oil pan
20 Starter motor
21 Oil drain plug
22 Primary fuel filter
C-3.2 Engine identification

All Perkins engines are identified by a serial number.
This number appears on the serial number data plate
attached to the left side of the engine block, near the rear
of the engine.
IMPORTANT
To order spare parts, Mecano Continental S.A may
need the data plate number to determine which
Number components are included in the engine.
1 Pulley
2 Alternator
3 Front lifting eyebolt
4 Water outlet
5 Valve gear cover
6 Rear lifting eyebolt
7 Air intake
8 Secondary fuel filter
9 Fuel injection pump
10 Oil filter
11 Crankshaft pulley
12 Water pump
Number
1 Data plate
2 Temporary Parts List number
3 List number
4 Serial number
5 Type

Page 35 of 90
C-3.3 Inspection of the engine alternator splitting.

Inspect the alternator to check that there are no loose
connections or that the battery is properly charged.
To check that the battery is properly charged, start the

forklift and turn the battery cut-off device. If the
alternator is working correctly, the forklift should not
stop.
ALTERNATOR
MAINTENANCE INTERVAL
Check after the first

and every 500 hours
Inspect the ammeter (if fitted) while the engine is

running to ensure proper battery and electrical system
performance. Make repairs as required. Check the
Check the belt tension
alternator and the battery charger for correct operation. every 50 service hours or weekly
When the engine is not run for long periods of time or if
the engine is only run for short periods, the batteries
may not fully charge. A battery with a low charge C-3.5 Instructions for replacing the belt:
freezes more easily than a battery with a full charge.
To replace the alternator belt or check belt tension,
follow the instructions given below:
WARNING -Fit the gauge as indicated in the following diagram (1)

at the centre of the longest free length and check the
tension. The correct tension is 535 N. If the belt tension
If the batteries are properly charged, the ammeter is below 250 N, adjust the belt to 535 N.
reading should be very near zero. (0 A)
C-3.4 Inspection of the alternator belt

The belt will be inspected and replaced with the engine
stopped. Check that the belt tension is correct. To
properly check the belt tension, use a Burroughs gauge.
To maximise the engine performance, inspect the belt

for wear and/or cracking (1). Replace the belt if it is
worn or damaged as follows:
-If the belt (1) has more than four cracks per 25.4mm (1
inch), it must be replaced.
-Inspect the belt for cracks, tears, glazing, grease and

Page 36 of 90
Adjust the belt as indicated below:
-Loosen the pivot bolt of the alternator (2) and the

adjusting bolt (3).
-Move the alternator to increase or reduce the belt

tension. Tighten the pivot bolt of the alternator and the
adjusting bolt to 22 N·m.
-If the system is dirty or contains stagnant water, flush

the cooling system with clean water.
-Close the radiator drain tap. Connect the radiator hose

if this was removed.
C-3.6 Changing the coolant
HAZARD
To change the coolant, make sure the vehicle is on
level ground, the cooling circuit is not pressurised
and the temperature is adequate.
Then follow the instructions below for draining:
-Stop the engine and allow to cool. Remove the filler MAINTENANCE INTERVAL
cap at the top of the cooling system.
Change coolant
-Remove the drain plug from the side of the engine every 2000 service hours or 2 years
block to drain the engine. Make sure the drain hole is
not blocked.
-Open the drain valve or remove the drain plug (1) from
the engine. If the radiator does not have a tap or a drain
plug, disconnect the hose at the bottom of the radiator.
HAZARD
Do not drain the coolant while the engine is still
hot and the system is under pressure because
dangerous hot coolant could be discharged.
-Fill the system with an approved antifreeze mixture.

The maximum fill rate is 5 litres per minute in order to
avoid air locks. Fill until water comes out of the engine
drain or bleed plug free of air bubbles. Tighten the
screw with the corresponding torque. Fit the filler cap.
-Clean up any remaining coolant. Check the engine for

coolant leaks.

Page 37 of 90
C-3.8 Replacing the air filter
WARNING
After running the engine, the coolant level may
IMPORTANT
vary. Check the level again after running the
engine for a few hours. Never run the engine without an air filter element
fitted or with a damaged air filter. Do not use air
C-3.7 Checking the coolant level filter elements with damaged pleats or gaskets. Dirt
entering the engine causes damage to components
and wear.
HAZARD
Hot coolant can cause serious burns. To open the
cooling system filler cap, stop the engine and wait
until the cooling system components are cool.
Check the coolant level only when the engine is stopped

and cool.
1) Slowly remove the cooling system filler cap to relieve

the pressure. AIR
FILTER
2) Maintain the coolant level within 13 mm below the
Air filter elements prevent particles from entering the
bottom of the filler pipe. If the engine has a sight gauge,
engine's air inlet.
maintain the coolant to the proper level on the sight
gauge.
The air filter is located on the engine. To clean or
replace the air filter, release the 3 fasteners on the
cover and remove the filter.
Clean the filter daily or every 8 hours

Change every year or every 1000 service hours
3) Clean the cooling system filler cap and check its Also:
condition. Replace the cap if the gaskets are damaged.
Reinstall the filler cap. -Check the pre-filter (if fitted) and the dirt cup daily for
accumulation of dust or dirt. Remove the dust and dirt
4) Inspect the cooling system for leaks. as required.
WARNING WARNING
Fill the cooling system on level ground with the Depending on the operating conditions (dust, dirt
engine cold. and particles), more frequent service of the air
filter element may be required.
-This replacement should be performed regardless of

the number of cleanings.

Page 38 of 90
Follow the instructions given below to change the There are two common methods for cleaning primary air
air filter: filter elements:
1) Release the 3 fasteners and remove the cover.

Remove the air filter.
2) Cover the air inlet with tape in order to keep dirt out.
HAZARD
Compressed air can cause personal injury. Use a
3) Clean the inside of the air filter cover and body with a
mask and protective clothing when using
clean, dry cloth.
compressed air. The maximum air pressure in the
nozzle must be below 207 kPa for cleaning
4) Remove the tape from the air inlet. Install the
purposes.
secondary element. Install a new or clean primary
element.
Compressed air
5) Install the air filter cover every time the dirty air filter Compressed air can be used to clean filters that have
elements are replaced with clean elements or proceed not been cleaned more than two times. Compressed air
to clean. will not remove deposits of carbon and oil. Use filtered,
dry air with a maximum pressure of 207 kPa (2.07 bar).
Before installing the new filters, carefully check that
there are no tears and/or holes in the filter material and
in the pipes to the engine.
Also inspect the gasket or the seal of the air filter

element for damage.
IMPORTANT
Keep an adequate supply of ORIGINAL MAST When the primary element is cleaned, always begin
EXPLORER air filter elements in stock as spare with the clean side (inside) in order to force dirt particles
parts for your forklift. toward the dirty side (outside). Aim the hose so that the
air flows inside the element along the filter in order not
C-3.9 Cleaning the air filter to damage the paper pleats. Do not aim jets of air
directly at the primary air filter element. Dirt could be
The primary element must be replaced at least once a forced into the pleats.
year. This replacement should be performed regardless
of the number of cleanings. Instructions for cleaning the Vacuum cleaning
air filter are given below. Vacuum cleaning is a good method for cleaning primary
filter elements that require dailycleaning because of a
dry, dusty environment. Cleaning with compressed air is
WARNING recommended prior to vacuum cleaning. Vacuum

cleaning will not remove deposits of carbon and oil.
Do not tap or strike the air filter element. Do not

wash the primary air filter element.
IMPORTANT
Visually inspect the filter before cleaning for
damage to the gasket and the outer cover. Discard
any damaged air filter elements.

Page 39 of 90
C-3.10 Engine oil level. Drain the oil pan with the engine stopped and the oil
warm. This draining method allows the waste particles
suspended in the oil to be drained properly.
HAZARD Failure to follow this recommended procedure will

cause the waste particles to be recirculated through the
engine lubrication system with the new oil. The oil pan
Hot oil and hot components can cause personal drain plug is shown below.
injury. Do not allow hot oil or hot components to
touch the skin. MAINTENANCE INTERVAL
Change the engine lubricating oil

every 500 service hours
To inspect the oil level:
-Maintain the oil level between the MIN mark (Y) and
the MAX mark (X) on the engine oil dipstick. Do not fill
the oil pan above the MAX mark (X).
IMPORTANT
C-3.11 Changing the engine lubricating oil Drain the oil when the oil is warm and the
contaminants are suspended and not settled in the
oil pan.
HAZARD Use one of the following methods to drain the oil from
the engine oil pan:
Hot oil and hot engine components can cause -If the engine is equipped with a drain valve, turn the
personal injury. Do not allow hot oil or hot valve knob to the left to drain the oil. After draining the
components to touch the skin. oil, turn the drain valve knob to the right to close the
valve.
-If the engine is not equipped with a drain valve, remove
the oil drain plug (1) to allow the oil to drain. If the
engine is equipped with a shallow oil pan, remove the
IMPORTANT bottom oil drain plugs from the ends of the oil pan.
-After draining the oil, the oil drain plugs must be

cleaned and installed. It is necessary to replace the
Do not drain the oil when the engine is cold. As the
gasket on the drain plug to prevent oil leaks.
oil cools, suspended waste particles settle on the
bottom of the oil pan. The waste particles are not
removed on draining the cold oil.
C-3.12 Changing the engine oil filter
Follow the recommendations given below to replace the
filter properly:

Page 40 of 90
1) Remove the oil filter with a suitable tool. 2) Start the engine and run at “low idle” for two minutes.
Perform this procedure in order to ensure that the
2) Clean the sealing surface of the oil filter (2). Ensure lubrication system has oil and the oil filters are filled.
that the union (4) in the oil filter head is secure. Inspect the filters for leaks.
3) Apply clean engine oil to the oil filter seal (3). Do not 3) Stop the engine and allow the oil to drain back into
fill the oil filters before installing them as this oil would the oil pan for a minimum of 5 minutes.
not be filtered and could be contaminated.
4) Maintain the oil level between the marks described
previously on the dipstick.
C-3.13 Fuel injectors
HAZARD
Fuel spilled onto hot surfaces or electrical
components can cause a fire.
Regular maintenance of the fuel injectors is not

necessary. The fuel injectors should not be cleaned as
cleaning with incorrect tools can damage the nozzles.
Only specialised staff must clean the injectors.
4) Install the oil filter.
IMPORTANT
Tighten the oil filter by hand (do not use tools)
according to the instructions given on the oil filter.
Do not over-tighten.
The fuel injectors should only be renewed if a fault
occurs or if a specialised injection system technician
orders their renewal.
Change engine oil filters
Some of the problems that may indicate that new fuel
injectors are needed are listed below:
-The engine does not start or it is difficult to start.
-It does not have enough power.

ENVIRONMENTAL
-The engine misfires or runs erratically.
PROTECTION -High fuel consumption.
-Black exhaust smoke.

Used filter waste should be handled by companies
authorised for this purpose according to the
-The engine knocks or there is vibration in the engine.
country where the forklift is located.
-Excessive engine temperature.
To fill the engine with oil
C-3.14 Priming the fuel system
1) Remove the engine oil filler cap.
If air enters the fuel system, the air must be purged from
the fuel system before starting the engine. Air can enter
the fuel system when the following conditions occur:

Page 41 of 90
-The fuel tank is empty or partially drained.
-The low-pressure fuel lines are disconnected or break. WARNING

-There is a leak in the low-pressure fuel system.
Fuel leaked or spilled onto hot surfaces or electrical
-The fuel filter is replaced. components can cause a fire.
-A new injection pump has been installed. To prevent possible accidents, turn the start switch to
the off position when changing fuel filters or water
Use the following procedure to purge air from the separator elements.
fuel system:
Clean up fuel spills and the area around the fuel system
-Remove the fuel injector cover. component to be disconnected immediately. Do not
allow dirt to enter the fuel system.
-Turn the ignition key to the ON position. Leave the key
switch in the ON position for three minutes.
-Turn the ignition key to the OFF position.
-Loosen the flare nuts (1) on the high-pressure fuel lines

on all fuel injectors.
-Observe the flare nut connection. Operate the starter

motor and run the engine until the air is removed from
the fuel. Number
-Tighten the flare nuts (1) to a torque of 30 N.m. 1 Screw
2 Element
3 Bowl
-Start the engine.
4 Bottom cover
5 Drain
6 Sensor connections
HAZARD Draining operations:
The fuel injection pump, battery and starter motor -Place a tray under the fuel filter to catch any fuel that
can be damaged if the starter motor is used might spill.
excessively to bleed or purge air from the fuel
system. -Open the drain (5).
-When clean fuel drains from the water separator, close

the drain (5). Tighten the drain by hand only. Dispose of
C-3.15 Changing the primary fuel filter the drained fluid correctly.
The Perkins engine fuel filter is located on the right side
of the engine. Operations to replace the primary fuel filter:
a) Turn the fuel supply valve (if installed) to the

OFF position.
b) Place a suitable container beneath the water
separator.
c) Open the drain (5).

Page 42 of 90
d) Tighten the drain (5) by hand pressure only.

e) Hold the element (2) and remove the screw (1).
Remove the element and the bowl (3) from the
base. Dispose of the used element.
f) Clean the bowl (4). Clean the bottom cover (6).
g) Install the new seal. Install the bottom cover of
the new element. Install the assembly onto the
base.
h) Fit the screw (1) and tighten to a torque of 8
N.m.
i) Remove the fuel container.
j) Open the fuel supply valve.
k) Prime the fuel system.
c) Remove the filter bowl (1) from the filter head
WARNING (3). Apply pressure to the element (4). Turn the

element to the left to release it from the filter
bowl and remove the element from the bowl.
Dispose of the used element.
The seals must be properly seated to prevent fuel d) Remove the seal (5) from the filter bowl and
leaks or to prevent air entering. clean the bowl. Check that the filter bowl
threads are not damaged.
e) Fit a new seal (5) onto the filter bowl (1).
f) Install the filter bowl (1) into the top of the filter
head (3).
Change primary fuel filter
g) Tighten the filter bowl by hand until the bowl
makes contact with the filter head. Turn the filter
bowl 90 degrees.
C-3.16 Changing the secondary fuel filter
WARNING
WARNING Do not use any tools to tighten the filter bowl.
Fuel leaked or spilled onto hot surfaces or electrical
components can cause a fire. h) Open the fuel supply valves (if installed).
Change secondary fuel filter

C-4 HYDROSTATIC SYSTEM MAINTENANCE
Regular maintenance operations for the forklift's

hydraulic installation include:
A) Checking and filling the hydraulic oil level as

necessary.
B) Cleaning and maintaining the radiating surfaces.

a) Close the fuel supply valves (if installed).
b) Clean the outside of the filter assembly. Open C) Changing the hydrostatic filters.
the fuel drain (2) and drain the fuel into a
suitable container. D) Changing the hydraulic oil.

Page 43 of 90
WARNING Change hydrostatic oil filter
after the first 50 hours
Extraordinary maintenance operations are usually and every 500 hours
necessary as a result of forklift component
malfunction. During maintenance cycles, avoid contaminating the
intake circuit whenever the filter cartridge is changed.
Extraordinary maintenance also includes: Use the hydraulic oil recommended by Mecano
Continental S.A that contains additives, according to
-Adjusting and regulating the pump during the initial viscosity grade ISO VG 46. It is recommended that
start-up. original MAST EXPLORER filters always be used.
-Disassembling and reassembling the pump and the C-4.2 Maintaining the hydrostatic pump
engine, or parts thereof.
It is very important that all parts and components of the
The following is recommended to ensure that the hydraulic installation are cleaned properly. This should
hydrostatic system is in good condition: be done before starting the forklift or after changing any
oil or mechanical elements.
-Carrying out all operations in a clean, dust-free
environment so that no foreign particles enter the
components.
WARNING
-Covering all pressure inlets with plastic plugs as soon
as the hydraulic lines are disconnected. It is necessary for the main connection operations
to be carried out in a clean, dust-free environment
-Replacing the seals every time the components are with any type of dirt that could enter the circuit
opened. We therefore recommend having several seal being immediately removed.
kits to hand before working on the components.
To guarantee that the operating temperature of the
hydraulic system remains within the permissible limits,
WARNING the condition and cleanliness of the oil-air heat
exchanger installed on the forklift must be checked.
The maintenance intervals for filter and oil

changes stated in this manual must be complied
with in order for the guarantee to remain valid.
C-4.1 Changing the hydrostatic pump's hydraulic oil

filter
The frequency of filter maintenance and replacement
depends on the pump's rotation rate, the type of fluid
used, the pump's starting and operating temperatures
and accidental or systematic contamination in the
forklift.
WARNING
After changing any mechanical element or oil, follow the
It is very important to change the hydraulic oil filter instructions given below:
after the first 50 hours of operation. If it is not
changed, the supplier's guarantee will be lost in Before starting the forklift
the event of any breakdown.
-Check the cleanliness of all the parts of the installation
that come into contact with the circuit's hydraulic fluid
Under normal operating conditions, the hydraulic oil (tank, tubes, heat exchangers, filters, etc.).
filters should be replaced:

Page 44 of 90
-Make sure nothing is blocking the pump's normal intake

and check for loose connections that could cause air to
enter the tubes, kinked or restricted lines, etc. IMPORTANT
-Install the pressure gauges on the high-pressure circuit
line and the low-pressure pump line. The pump has Make sure the pump is set to the zero
three 1/4" quick-connect terminals for pressure gauges, displacement position (the gear stick must be in
two for high pressure (400 bar) and one for the supply the neutral position, i.e. not in either forward or
pressure (10-30 bar). reverse).
Filling the hydraulic tank Correct operation of the loading pump is indicated by
the pressure gauge installed in the pump's supply circuit
(minimum pressure port), which indicates a minimum
IMPORTANT pressure of a few bar (10-25 bar).
-Run the pump in both directions and make sure the

direction of rotation of the driven parts is correct.
Before filling the tank, check that it is clean and
with no signs of residue, particles, rust, etc. -Run the transmission until you are sure that all air has
inside. been eliminated and there is no mixture of air and oil.
This usually takes a few minutes.
-Increase the rotation speed and check that the
IMPORTANT pressure in the loading circuit reaches 18-20 bar and

that the depression on the intake line pressure gauge
does not exceed values of 0.5 bar with cold oil and 0.2
bar with hot oil.
Use a 10-micron filter when filling the hydraulic
fluid to prevent foreign bodies from entering the -Gradually increase the load, monitoring the maximum
installation. operating pressure on the high-pressure gauge.
Even new oil may contain impurities. Also fill the tank -During the starting phase, check the hydraulic fluid
and all other large-capacity components with fluid level in the tank and, if necessary, fill to the appropriate
(filters, heat exchangers). level.
Fill the hydraulic pump and motor with oil via one of the Checking the hydrostatic pump performance
drain ports and make sure the casing is at least 50%.
full To check the pump's performance, install one pressure
gauge (up to 60 bar) at the supply pressure intake and
another (up to 600 bar) at the high-pressure intake.
HAZARD
Do not run the engine and the hydraulic pump
before filling. The components may be seriously
damaged.
On starting the forklift
The vehicle must be started and all of the air present in

the hydraulic circuit eliminated before said circuit is
used to lift heavy loads.
To do this, with the emergency stop connected (the

forklift will not be able to start), keep the engine turning Always pay maximum attention to moving parts and
over with only the starter motor (at less than 500 rpm) comply with all current safety standards.
until the entire circuit has filled with oil (this operation
tends to require two or three start phases lasting some
5 seconds each).

Page 45 of 90
If there is no other option but to tow it, the following
HAZARD instructions must be followed:
Carry out this test in the shortest time possible to

avoid overheating the pump and the installation.
IMPORTANT
The H70/80 4WD models cannot be towed as they
For closed circuit pumps, make sure the external have a negative brake on the front differential and
maximum pressure relief valve is correctly attached to
it is preferable for the forklift to be repaired on
the pump and that it properly protects the pump. Follow
site.
the procedure outlined below:
-Cover the high-pressure openings with plugs and seals

capable of withstanding at least double the maximum
pressure of the pump.
-Turn the pump at 1200 rpm with zero displacement;

IMPORTANT
with the oil at around 50ºC, check that the supply
For the H70/80 2WD models, the following
pressure is around 18-20 bar.
operations should be carried out.
-Slightly increase the pump displacement; check that
the supply pressure does not suddenly drop and the There are 2 methods for releasing the Linde hydrostatic
operating pressure is the same as the rating pressure of pump:
the maximum pressure relief valves.
Method one: Remove plugs A and A’ shown in the
-If the supply pressure suddenly drops and the pump following photos and join with a pigtail.
does not open the maximum pressure relief valves, the
wear and internal play of the components have probably
reached such a level that the component needs
overhauling or replacing.
C-4.3 Hydrostatic regulation and pressure

measurement
HAZARD
Any modification to the hydrostatic pump must be
communicated to and authorised by the Mecano
Continental, S.A. Technical Support Department.
HAZARD
The hydrostatic pumps must not be regulated or
adjusted on site. Contact the Mecano Continental
S.A. Technical Support Department.
C-4.4 Releasing the hydrostatic pump for towing the

forklift
Towing the forklift is only recommended if there is no

other alternative as it can cause serious damage to the
transmission. If possible, the forklift should be repaired
on site at its current location.

Page 46 of 90
Method two: Loosen the high-pressure valves B and B'

by 3 or 4 turns.
IMPORTANT
Battery electrolyte contains sulphuric acid which
can cause burns on contact with the skin or eyes.
-Wear safety goggles and gloves and move the battery

carefully to avoid electrolyte leaks. Also:
-Keep all metal objects (watches, rings, chains) away

from the battery terminals as they could cause a short
circuit resulting in burns.
-Before connecting or disconnecting the battery, turn off

all switches in the cabin.
-To disconnect the battery, first disconnect the negative

terminal (-) from the earthing point.
-To connect the battery, first connect the positive

terminal (+).
-Recharge the battery away from the forklift in a well-

ventilated area.
-Never approach with objects that could produce

sparks, open flames or cigarettes.
-Avoid placing metal objects on top of the battery. This

could cause dangerous short circuits, especially during
recharging.
-Given that the electrolyte is highly corrosive, avoid any

contact with the forklift chassis or with electrical or
C-5 ELECTRICAL SYSTEM MAINTENANCE electronic components. If this does occur, contact an
authorised support centre.
HAZARD ELECTRICAL
All maintenance work on the electrical system
HAZARD
must be carried out with the engine off, the parking
brake on and with all working parts resting on the There is a risk of the battery exploding or short
ground. circuiting. An explosive mixture of hydrogen gas
forms when recharging the battery.
C-5.1 Battery
The battery fitted on this forklift truck does not need
maintenance. Check:
-That all cable terminals are securely attached to the

battery posts. To tighten the terminals, always use a
HAZARD
spanner, not pliers.
The battery electrolyte contains caustic sulphuric
-Protect the posts by coating them with pure vaseline or acid. If it contacts the skin, immediately wash off
battery terminal protector spray. with soap and plenty of water. If the acid contacts
the eyes, flush with abundant water and see a
-If the forklift is not going to be used for a long period of doctor.
time, remove the battery and store in a dry place.

Page 47 of 90
ENVIRONMENTAL
PROTECTION
Process the used battery as waste to protect the
environment.
C-5.2 Fuses and relays

The electrical installation is protected by fuses installed
at the back of the cabin. Before replacing a blown fuse
with another of the same amperage, find and correct
whatever caused the fuse to blow otherwise the
problem will continue.
The fuse box that is located under the bonnet to the left
of the engine is shown below.
IMPORTANT C-6 TRANSMISSION SYSTEM MAINTENANCE.

GREASING THE FORKLIFT
Do not use fuses with a higher amperage than MAINTENANCE INTERVAL

indicated as this may damage the electrical
installation. Grease axles, mast and mast pins
every 30 days or 200 service hours
FUSE No. NAME AMPERAGE (A)
The rear axle, mast, tilt cylinder linkage, mast pins and
1 Rotating beacon 15
other elements requiring lubrication must be greased as
2 Windscreen wiper 25 shown in the following figures using adequate amounts
3 Hour meter 5 of grease.
4 Forward-reverse lever 10
Greasing the rear axle: the axle has two grease points
5 Full-beam headlights 15
per wheel as shown in the following diagram:
6 Dipped headlights 15
7 Right rear light 7.5
8 Left rear light 7.5
9 Indicators 10
10 Horn 10
11 Engine heater 30
12 Battery charge indicator 7.5
13 Gear stick 10
14 Fuel level 15
15 Work light 15
16 Negative brake 15
17 Service brake 10
18 Forward drive 5
19 Reverse 5
20 Heating 25
21 General fuse (large) 50

Page 48 of 90
Visually inspect the forks, paying particular attention to

Rear axle grease points on H70/80 DA: points 1, 2 and 7 shown in the following diagram. If
there is a fault, replace with an original spare part.
WARNING
All hinges, fork heads and other articulations must
WARNING be oiled prior to use as required.
C-8 MAST MAINTENANCE AND GREASING

The rear axle has 2 grease points per wheel and
the front axle has no grease points as it is a live
axle The runner blocks and rollers installed on the mast
guides must be greased.
The mast rails should also have liquid grease so that

MAINTENANCE INTERVAL the runners produce minimum friction and wear when
sliding.
Grease the 2 grease points
every 30 days of operation All grease points on the masts are broken down into the
areas shown below (A, B C and D).
C-7 FORK CHECK

WARNING
There may be slight differences between the
Check the following critical points photos shown below and your specific mast
every 30 days or 200 service hours depending on whether your forklift has a duplex or
triplex mast.
Details on each area are given below:

Page 49 of 90
Points 2, 4 and 6 are in the same position on the other

side (mirror-image).
Area B(This area is for the triplex mast model only).
Points 2 and 4 are shown on the following photo:
Area C
Points 1, 2, 3 and 4.
Area A
Point 4 is on the lower face:
Below is a close-up of elements 1, 3 and 5:

Page 50 of 90
Area D
We must also consider the two grease points on the tilt

IMPORTANT
cylinder linkage and the mast pins as shown below:
The lifting chains are safety elements. Chemical
cleaning products, acids and bleach must not be
used as they may damage the chains. Apply spray
grease that is recommended for this purpose.
C-9 TYRE PRESSURE
The air pressure used has a direct effect on the tyre's

service life. The tyre pressure must be checked every
100 service hours when the forklift is unloaded. Check
that the tyre pressure complies with the following table:
Checking the mast chains:

Check the pressure
Check mast chains
every 30 days
Model Tyre Pressur

Pay special attention to points 1 to 7. If there is a fault, e
replace with an original spare part. H70 (2WD and
16x70-16.5 14PR 5 bar
4WD)
H80 (2WD and
MAINTENANCE INTERVAL 420/75 R20 5 bar
4WD)
H70 (2WD and
Grease the chains 400x60-15.5 14PR 4 bar
4WD)
every 30 days or 200 service hours
H80 (2WD and
280/80 R20 4 bar
4WD)
IMPORTANT
If the tyre pressure is wrong, correct as soon as
possible to prevent hazards.

Page 51 of 90
Operating a forklift truck with low tyre pressure will have -Put the valve dust caps back on after checking or filling
the following effect on the tyres: the tyres.
-For special operations, for example on sandy terrain,

the air pressure can be modified after consulting the
after-sales department or the tyre manufacturer.
C-10 TIGHTENING OF WHEEL BOLTS
Check bolt torque

Tighten all wheel bolts daily during the first week of

operation.
-Excessive flexing
-Overheating
-Excessive strain on fabric
-Bulging of sidewalls IMPORTANT
This results in damaged sidewalls and stretched
individual strands of fabric. The tightening torque is 270 N·m for the front
differential and 270 N·m for the rear axle.
IMPORTANT Wheel nuts must also be tightened daily after each

wheel change during the first week of operation.
A high pressure is dangerous as it transmits

excessive tensile strain to the fabric and the tyre is
therefore susceptible to punctures and cuts.
Take the following precautions when servicing the tyres:
-Always stand to the side of the tyre so you are shielded

by the vehicle to protect yourself against possible
explosions.
-On filling a tyre on a split-rim wheel, check exactly if the

loose ring pieces are in the right position as a ring flying
off the rim may cause fatal injuries.
Apply tightening torque in a criss-cross
-Use a safety nozzle (that you do not have to hold pattern with a torque spanner to 270
manually) with a hose that is long enough for you to N.m.
stand outside the danger zone when filling the tyre.
-Never cut or solder a rim if the tyre contains C-11 TECHNICAL SPECIFICATIONS OF FORKLIFT
pressurised air. FLUIDS
-Never assemble rim pieces of different sizes and never
use damaged or faulty pieces. See the service manual The following table shows the fluids used in the forklift:
for authorised tyre and rim sizes. Do not fit tyres with a
different tread.
-Remove the air before removing foreign bodies from

the tyre.

Page 52 of 90
LIST OF LUBRICANTS USED
LUBRICANTS TYPE Specification Typical values
Density at 15ºC (kg/l) 0.835

Engine oil ISO 10W-40
Kinematic viscosity -
Hydraulic oil ISO VG 46
-40ºC (cP) 1100
Chains Chain spray
40ºC (cSt) 18.2
Extreme-pressure adhesive
Mast 100ºC (cSt) 6.2
grease
Fuel Diesel Viscosity index >300
Colour green
Differential carrier oil SAE 75W-80, API GL-4
Flash point (OC) 125ºC
Differential oil SAE 75W-80, API GL-4
Pour point -60ºC
Brake fluid LHM Super mineral oil
Lithium soap-based grease
Grease points
(DIN 51825-KPF2 N-20 ANTIFREEZE
Penetration grade 2, lithium
soap)
Antifreeze is usually made of three elements: water,
additives and glycol. We recommend using an
antifreeze with a minimum concentration of 50% in
HYDRAULIC OIL PROPERTIES engine cooling systems.
The hydraulic oil used in our forklift trucks allows high-

pressure operation without hardly any variation in
viscosity as temperature changes. Thanks to a suitably
high viscosity index, the oil maintains a suitable
viscosity throughout the forklift's entire operating
IMPORTANT
temperature range.
Do not use the following types of water in cooling
This oil complies with the following standards: systems: Hard water, soft water that has been
softened with salt and seawater.
ISO/DIS 6743 Part 4 Category HV
Many engine failures are a result of the cooling system.
DIN 51524 Part 2 and 3 Category HLP/HLPV The condition of the coolant is also important for it to do
AFNOR NF E 48602 Category HV its job properly. Never work on an engine without a
thermostat in the cooling system. Thermostats help
AFNOR NF E 60 200 Category HV
keep the engine coolant at the right operating
temperature.
BRAKE FLUID The coolant's glycol content helps protect against

boiling over, freezing and water pump cavitation. A
The brake fluid is a green, special, mineral oil-based mixture is used.
fluid that is to be used to initially fill and successively
refill the combined brake-suspension circuits.
C-12 MAINTENANCE PROGRAMME FOR THE
This fluid offers notable lubricating power, which favours PERKINS 1104D-44T SERIES ENGINE
optimum performance of the mechanical parts present
in the hydraulic circuits.
It is also characterised by an extremely low freezing

point and a very high viscosity index and can therefore
WARNING
be used without drawbacks in a wide temperature
range. Before performing any maintenance work or
procedure, make sure you have read and
understood all the safety information, warnings and
instructions.

Page 53 of 90
The following programmes must be performed

according to the interval that comes first: When required
Replace the battery
PERKINS maintenance programme Disconnect the battery or battery cable
When required Clean the engine
Daily or every 8 service hours Clean or replace the air filter
Every 50 service hours or weekly Prime the fuel system
Every 500 service hours Daily
Every 500 service hours or year Check the coolant level
Clean the air filter
Every 3000 service hours Check the oil level
Every 3000 service hours or 2 years Drain the primary fuel filter or water separator
Every 4000 service hours Inspect belts
Every 12,000 service hours or 6 years Walk-around inspection of engine
KEY FOR FOLLOWING TABLE Every 50 service hours or weekly
Drain fuel tank water or sediment
The preventive maintenance intervals are indicated for
Adjust, inspect or replace the alternator belt
normal operating conditions. When engine performance
Every 500 service hours or year
must be adjusted to local standards, it may be
necessary to adapt the maintenance intervals and Check the battery condition
procedures to guarantee correct engine performance. Check the condition of the engine breather
Clean or replace the engine air filter
As part of good preventive maintenance, look for leaks Replace the primary fuel filter
or loose fasteners during each check. Change engine oil and oil filter
Replace the secondary fuel filter
Inspect hoses and clamps
Clean the radiator
Inspect the engine valve lash
Inspect the aftercooler core
Inspect the alternator
Inspect the engine mounts
Inspect the starter motor
Inspect the turbocharger
Inspect the water pump
Inspect, adjust or replace the alternator belt
Test or change the injectors
Every 3000 service hours or 2 years
Change the cooling system coolant
Clean and test the fan core
Every 12,000 service hours or 6 years
Change the cooling system coolant

Page 54 of 90
Section D
SAFETY
CONTENTS
D-1 GENERAL OBSERVATIONS
D-2 CONDITIONS TO BE MET BY OPERATORS
D-3 RESIDUAL RISKS
D-4 NOISE EMISSIONS AND VIBRATIONS
D-5 DESCRIPTION AND SAFETY DEVICES
D-6 SAFETY RECOMMENDATIONS
D-7 RULES ON DRIVING THE FORKLIFT
D-8 AT THE END OF THE DAY
D-9 GENERAL SAFETY MEASURES REGARDING THE ENGINE
D-10 GENERAL SAFETY MEASURES REGARDING THE ELECTRICAL SYSTEM
D-11 PERSONAL PROTECTION

Page 55 of 90
D-1 GENERAL OBSERVATIONS

D-3 RESIDUAL RISKS
This forklift has been designed in accordance with the
provisions of section 1.1.2 “Principles of safety Although Mecano Continental S.A has made every
integration” of point 1 “Essential health and safety possible effort to ensure this forklift's safety by way of its
requirements” of annex I of Directive 2006/42/EC on the design and manufacture, it considers that residual risks
approximation of the laws of Member states relating to may occur as a result of the operator's actions during
machinery. operation.
Most accidents involving forklifts and their maintenance Some examples are given below:
or repair are the result of not complying with the most
basic safety precautions. -Risks due to working or driving too fast for the loading
conditions or the area of operation.
It is therefore necessary to always be aware of potential
risks that could arise as a result of operating the -Risks due to using incorrect methods for checking or
forklifts, paying constant attention to the effects that replacing a hydraulic valve (residual pressure not
each action performed could have. discharged – uncontrolled movements).
-Risks due to using incorrect methods for disassembling
IMPORTANT parts, such as cylinders without having secured moving

parts correctly (risk of the moving part accidentally
falling).
Being aware of potentially dangerous situations -Risks due to the forklift accidentally overturning without
could prevent an accident. the operator using the seat belt.
D-2 CONDITIONS TO BE MET BY OPERATORS D-4 NOISE EMISSIONS AND VIBRATIONS

The person that usually operates the forklift must meet All MAST EXPLORER forklifts have a guaranteed
the following conditions: sound power level according to Directive 2000/14/EC
of the European Parliament and of the Council on the
Medical: approximation of the laws of the Member States
Before operating the forklift and during operation, the relating to the noise emission in the environment by
operator must not consume alcoholic beverages, drugs equipment for use outdoors.
or other substances that could impair his or her
psychological and physical condition and consequently In accordance with the provisions of EN 12053 and
the ability to drive the forklift. EN-ISO 4871, the emission sound pressure level at the
operator's position, for a complete operational cycle, is
Physical: below 80 dB.
The operator must have good eyesight, good hearing,
good coordination and the ability to safely perform the
functions needed to operate the forklift as specified in
this manual. WARNING
Mental:
The ability to understand and apply established safety Noise measurements have been taken under the
standards, rules and precautions; the operator must be following operating conditions: idling, lifting and
alert and use good judgement for his or her own safety movement.
and that of others and the operator must make every
effort to do the work correctly and responsibly.
The vibration level to which the operator's body is
Training: exposed has been measured using representative and
The operator must have carefully read and studied this technically comparable forklifts as indicated in EN
manual, the attached charts and diagrams and the 14253:2004, Royal Decree 1311/2005 and Royal
warning and hazard stickers; he or she must be Decree 1311/2005 Technical Guidelines in order to
specialised and competent in all aspects regarding minimise risks for the operator.
operation and use of the forklift.
These measurements have been taken by an
authorised control body with the forklift in motion and
values not exceeding 0.74 / ଶ have been obtained.

Page 56 of 90
IMPORTANT WARNING
Any arbitrary modification to the forklift causes If the emergency stop button is pushed, the engine
the sound power values to vary. will not start.
D-5 DESCRIPTION AND SAFETY DEVICES Safety cabin: this robust element protects the driver in
All MAST EXPLORER forklifts have all of the means the event of the load falling off of the forks or the forklift
necessary to guarantee their safe use. overturning.
In designing these forklifts, all possible risks have been Fork carriage: this is a rigid element located on the
taken into account. As such, covers and guards have front of the mast which moves along with the load
been fitted to protect the operator from any hazards that platform. It increases the support surface of the loads,
may be encountered during operation of the forklift, preventing them from falling on top of the operator.
such as becoming trapped in the engines and moving
parts of the transmission, electrical system, etc. Bonnet: protects the engine from any unauthorised
handling.
Chassis: the forklift is totally protected to prevent any

contact with the electrical circuits, tyres, etc.
Signalling beacon: light indicating that the forklift is

running. It is located on top of the rear of the cabin.
HAZARD
If the safety covers and guards are removed
(which is only authorised during maintenance),
they should be refitted as soon as the repair is
completed.
The forklift has an emergency stop button located next

to the hydraulic controls and the corresponding risk
indicator diagrams.
Acoustic warning alarm: when the forklift is moving in
Emergency stop: the emergency stop is located on the reverse, an audible signal is activated.
right-hand side of the operator, next to the hydraulic
control joystick. It automatically brings the engine to a Seat belt: located on the seat and worn by the operator.
halt in the event of an emergency or problem. On those
vehicles fitted with a negative brake, this will come on
when the emergency stop button is pushed.
HAZARD
Wearing the seat belt is compulsory to prevent
serious injury in the event of an accident.
Key: locking device that prevents any unauthorised

persons from using the vehicle.

Page 57 of 90
D-6 SAFETY RECOMMENDATIONS -Do not, under any circumstances, increase the
weight of the counterweight by adding additional
The driver of any motorised industrial forklift must be at
loads, especially by having people climb onto the
least 18 years of age and be expressly assigned by the
vehicle. If the load capacity of the forklift is never
company.
exceeded, resorting to such tricks will never be
necessary.
-Do not use two forklifts simultaneously to move

IMPORTANT heavy or very large loads as this is a dangerous
operation that requires very special precautions. This
should only be attempted in exceptional circumstances
Make sure that new operators are trained, and under the supervision of the head maintenance
monitored and assisted by expert staff who are technician.
qualified to operate forklifts.
-To lift a load safely, fully insert the forks
Nobody who fails to meet these requirements should be underneath the load, lift the load slightly and
allowed to drive an industrial forklift truck. immediately tilt the mast backwards.
-Before driving, check that the load is balanced and

secure on its support. Whenever the forklift is laden,
IMPORTANT keep the forks lowered and with the load tilted back
towards the driver. This will ensure greater stability.
The driver must be aware that, in addition to those

accidents that he or she may suffer, the equipment
that they are operating can cause injury to other
people if all of the safety rules are not carefully
followed.
It is not the forklift truck in itself that is dangerous but

rather the way in which it is used. On using this type of
equipment, hazards similar to those present when
driving other vehicles may occur: bumps, impacts,
turning over, trapped limbs, etc.
-Before undertaking any manoeuvre, check that there
Some safety considerations that must be followed are
is nobody in the immediate vicinity of the forklift,
listed below:
especially when reversing.
-Never exceed the forklift's load capacity. Failure to
-When raising or lowering the forks, the driver must
follow this rule may cause the vehicle to overturn,
make sure his or her hands or feet, or those of any
risking injury to both the driver and to his or her
colleague, cannot become trapped.
colleagues. See load diagrams on the forklift for this
purpose.
-Do not point the forks towards people working

close to walls or boxes.

Page 58 of 90
-Nobody should stand or walk under the raised -Drive slowly over any wet, slippery or uneven terrain.
forks, even when the vehicle is unladen.
-Brake progressively, not sharply.
-Respect the signs and driving rules established by the

company.
-Only follow the set routes.
-The forklift truck must not be used to carry passengers.

The driver will be held responsible for any
consequences resulting from failing to obey this rule.
-Do not drive with the load in the raised position since
doing so would greatly decrease the stability of the
vehicle. The load should always be carried in the lowest
-Never leave the forklift with a raised load. possible position.
D-7 RULES ON DRIVING THE FORKLIFT

-Do not allow yourself to become distracted from the
task of driving.
-Look in the direction in which the vehicle is moving,

maintaining good visibility at all times.
-Drive at a reasonable speed.
-Avoid accelerating, changing direction or stopping

suddenly.
-Take all turns at a low speed, using the horn to warn

anyone nearby. -With platform forklifts, the vehicle should be driven with
the load in front. The driver would then not be crushed
-Indicate each manoeuvre that is to be carried out with in the event of a fall.
sufficient advance warning.
-Use the horn when approaching bridges, crossroads, -Whenever driving with the vehicle unladen, the forks
pedestrians, animals, etc. should be kept at around 15 cm from the ground.
-Take special care with loads when passing under

bridges or through doorways.
-If it is necessary to drive on slopes, proceed forwards

when going up and in reverse when going down. Do not
turn on a slope.
IMPORTANT
If the size of the load prevents good forward
visibility, the driver should proceed in reverse.

Page 59 of 90
-Stacks of material should be placed tidily and safely. If member of staff.

stacking reels, remember that they can roll around. Pay
attention to where they are left and make sure they are -The operator must never stand between the mast and
secured using wedges. the overhead guard of the forklift. If it is necessary to do
so, lock all controls to prevent any unexpected
-Do not use the forklift to push other vehicles. If it is movement of the mast.
necessary to tow another vehicle, this must be done
using a rigid bar at a very low speed.
-Make sure that the combined weight of the forklift and

the transported goods does not exceed the maximum
load capacity for the terrain.
-Before driving onto walkways, platforms, gangways,

etc., make sure that they can bear the weight of the
vehicle.
-When driving behind another vehicle, maintain a

distance equal to approximately three times the length
of the forklift. This will help prevent accidents in the
event that the other vehicle needs to brake suddenly.
-When passing through narrow passages, the driver

must take care that his or her head, arms and legs do D-9 GENERAL SAFETY MEASURES REGARDING
not stick out past the width of the vehicle. THE ENGINE
This section indicates the basic safety precautions that
-When tilting the forks or the backplate forwards, the must be followed. Read and make sure you fully
stability of the vehicle is reduced. When it is necessary understand the basic precautions that appear in this
to put down a load using these mechanisms, do not lift it section before operating, lubricating, carrying out
any higher than necessary and, when lowering, do so maintenance on or repairing this product.
slowly.
The operator in charge of engine maintenance must
-Tin and sheet metal containers can break and shoot observe the following safety recommendations:
out at nearby co-workers. Avoid accelerating or braking
sharply, as well as turning at speed. -Make sure that all warning stickers are clearly legible.
Clean or replace any stickers that cannot easily be read
-If during the course of a job it is necessary to stop, or that have illustrations that cannot be seen.
unless said stop is for a very short period of time, the
engine should always be turned off. -Do not wear any clothing or jewellery that could
become trapped in or wrapped around the controls or
D-8 AT THE END OF THE DAY any parts of the engine.
-At the end of the working day, the forklift should be
-Make sure that all guards and covers are correctly
parked in the place specifically set aside for this
fitted on the engine.
purpose, where it will be protected from the elements.
-Keep the engine free from foreign materials. Remove
-When parking the forklift, the engine should be turned
any rubbish, oil, tools and other items from the
off, the parking brake applied, the battery disconnected
walkways and from the steps.
and the key removed from the ignition.
-Never store maintenance fluids in glass containers.
-The forks should be left in the lowest possible position
Drain all liquids into a suitable container.
resting on the ground.
-Do not disassemble any component or part of the
-The forklift should always be parked on level ground. If
hydraulic system without having first released the
for any exceptional reason it is necessary to leave it
pressure from the system. Failure to do so could result
parked on a slope, the wheels must be carefully blocked
in injury.
using wedges and the parking brake applied.
-Do not touch any part of the engine whilst it is running.
-The driver must not make any repairs or adjustments to
Allow the engine to cool before carrying out any
the forklift. Any anomaly observed during work, no
maintenance work on it.
matter how small, must be duly reported to a senior

Page 60 of 90
-The electrolyte is an acid and may cause personal -Keep away from moving parts when the engine is
injury. Do not allow the electrolyte to come into contact running.
with skin or eyes. Always wear protective goggles when
servicing the batteries. Wash your hands after touching
the batteries or the connectors. The use of gloves is
recommended. IMPORTANT
Some moving parts are not visible when the
engine is running.
-Do not start the engine if any of the safety guards have
been removed.
-Do not remove the filler cap or any component of the

cooling system whilst the engine is hot and the coolant
-Do not smoke whilst filling the fuel tank. is under pressure. Doing so could cause dangerous hot
coolant to overflow.
-Do not carry out any welding on pipes or tanks that
contain flammable liquids. -Do not allow any sparks or naked flames near the
batteries (especially during the battery recharging
process). The gases given off by the electrolyte are
highly flammable. The battery fluid is harmful to the skin
and especially to the eyes.
-There should only be one person at the engine

controls.
-Make sure that the engine is only controlled from the

control panel or from the operator's seat.
-Do not bend pressurised pipes. Do not hit pressurised -If the pressurised fuel comes into contact with anyone's
pipes. Do not install pipes that are bent or damaged. skin, seek medical attention immediately.
-Do not place any objects near the moving fan blades. -Fuel and oil (especially used oil) can be harmful to
The fan blades will launch or cut any objects that touch some people's skin. Wear protective gloves or use a
them. Wear protective goggles to prevent possible eye special protective solution for the skin.
injuries caused by flying objects.
-Clean up any spilled fuel.

HAZARD
-Any materials that have been splashed with fuel should
be set aside at a safe distance.
Before working on pressurised lines (hydraulic oil,
compressed air) and/or disconnecting hydraulic
-While running, the engine cannot be cleaned or
elements, make sure the line is not pressurised
adjusted, and neither lubricant nor fuel can be added.
and no longer contains hot fluid.
-Do not make any kind of adjustment without first
learning how to do so correctly.
-Make sure that the engine is not started in any location

where doing so could lead to a high concentration of
toxic emissions.
-Keep other people at a safe distance whilst either the -Do not wear clothing that has been stained with
engine or any auxiliary equipment is running. lubricant. Do not put materials that have been stained
with oil in your pockets.
-Keep loose clothing and long hair away from moving
parts. -Dispose of used lubricant in accordance with local
environmental pollution regulations.

Page 61 of 90
-The material used to make some of the engine -The electrical conductors must be protected against
components (some of the seals, for example) can be wear and should be checked regularly for damage;
extremely dangerous if burned. Never allow this burnt change as required.
material to come into contact with skin or eyes.
-Unprotected electrical conductors should not be
-Make sure that the transmission control lever is in the allowed to rest on pipes containing oil or brake fluid.
neutral position before starting the engine.
-Take extreme care when carrying out emergency D-11 PERSONAL PROTECTION
repairs in adverse conditions.
All forklift truck drivers must be provided with the
following personal protective equipment:
-Do not allow compressed air to come into contact with
skin. If compressed air breaks the surface of your skin,
Protective helmet, compulsory when the operator's
seek immediate medical attention.
cabin does not feature an overhead guard. In any case,
it is essential that all drivers have a helmet for use
outside the forklift.
WARNING Non-slip safety boots, with reinforced toecap.
Do not clean the engine whilst it is running. If cold Safety gloves. Although not necessary for driving, they
cleaning fluids are applied to a hot engine, some should be available for use in any possible emergency
engine components can become damaged. and for handling materials.
Work clothes. Forklift truck drivers should not wear any

loose clothing that could get trapped in or around the
D-10 GENERAL SAFETY MEASURES REGARDING moving parts of the vehicle.
THE ELECTRICAL SYSTEM
-Work on the electrical system should only be carried Ear protectors. When the noise level exceeds the
out by specialised personnel with suitable work and established safety margin and in any case when it is
verification methods. above 80 dB (A), the use of earphones or earplugs will
be compulsory.
-Stop the engine before working on the electrical
system. The forklift is not designed for working with hazardous
materials such as explosives, toxic, flammable or
-All cables and plugs should be marked up before being harmful substances, nor for working in explosive
disconnected and must be protected against contact environments or in bad weather. It is therefore
with metal parts by fitting them with protective caps or prohibited to use the vehicle in environments containing
taping them with insulation tape, for example. flammable or explosive materials.
-Any defects in the electrical installation (broken

insulation, for example) must be repaired immediately.
-The battery's negative (-) cable must always be

IMPORTANT
disconnected before starting any cleaning operation. It
is not enough to simply turn off the battery's cut-off The service life of the forklift is estimated at 6
switch. years, after which time the vehicle should either be
decommissioned or MECANO CONTINENTAL, S.A.
-If it is necessary to clean the interior of the cabin with should be asked to carry out a complete
water or water-soluble detergents, it is important to take inspection of it.
special care not to damage the electronics system. Use
only authorised solvents. Avoid breathing in the fumes
from any thinners used.
-After the cleaning operation, make sure all electrical

components are completely dry before reconnecting the
IMPORTANT
battery.
MECANO CONTINENTAL, S.A. will not be held
responsible for improper use of the forklift,
whatever the circumstances.

Page 62 of 90

Page 63 of 90

Page 64 of 90
Section E
TROUBLESHOOTING
CONTENTS
E-1 MALFUNCTION AND FAULT FINDING
E-2 PROBLEMS - CAUSES- SOLUTIONS
E-2.1 Movements
E-2.2 Electrics
E-2.3 Brakes
E-2.4 Mast
E-2.5 Engine

Page 65 of 90
E-1 MALFUNCTION AND FAULT FINDING

This chapter gives the operator guidelines on the most typical fault repairs but also gives a clear indication of
maintenance work that may only be carried out by specialised technicians as a result of the responsibility resulting
from such repairs. If in doubt, do not undertake any work on the forklift without first talking to a specialised
technician.
HAZARD
All maintenance, troubleshooting or repair work must be carried out with the engine turned off, the mast
lowered or resting on the ground, the parking brake on and with the key removed from the steering
column.
E-2 PROBLEMS - CAUSES- SOLUTIONS
E-2.1 Movements
PROBLEM CAUSE SOLUTION

-blown fuse
The forklift runs OK in one direction -change fuse
-gear stick not sending signal to
but does nut run properly in the other -change electro-valve
change direction
direction -check hydraulic circuit pressures
-electro-valve not working
-engine coupling to the hydrostatic
pump broken
The forklift will not go in either -check engine coupling
-negative parking brake on
direction but the engine will start -take off parking brake
-driver not in seat
-fuses, gear stick
The forklift will not go in either
-check nylon flywheel coupling
direction and will not rotate or pick up -engine coupling defect
between engine and pump
loads
-wait until the working temperature is
reached
The forklift moves without touching -the forklift is cold -adjust engine revolutions to 900 to
the accelerator -engine unbalance 950 rpm
-adjust hydrostatic pump starting
point
The forklift has no power -hydrostatic pump filter blocked -change filter
-change oil
The forklift is losing power when hot -degraded oil -check fuses
-check operating pressures
-check gear stick
-electro-valve error
The forklift won't go into 2nd gear -check electro-valve
-insufficient pressure
-check minimum pump pressure
Swap the gear pump outlets to check operation. If the forklift then turns, the
The forklift won't turn problem is the gear gump unit and if it still does not turn, change the
steering
-priority vale not regulated -change pump
The steering is stiff
-pump is damaged -regulate valve

Page 66 of 90
E-2.2 Electrics

-Blown fuse, short circuit in wire,
The hour meter is not working -check fuses and alternator charge
alternator
The indicators, headlights and horn -no power reaching them -check fuses, connections or horn
are not working -poor connections -if there is power, replace bulbs
E-2.3 Brakes

-fill tank
The brakes don't work and the pedal -no brake fluid in the tank -bleed circuit to expel air
goes to the floor -no pressure to the pump -change seals
-change pump
E-2.4 Mast

-check thermostat and thermostat
-oil temperature above 90ºC
fuse to see if fan comes on
The load isn't lifted -distributor not regulated
-regulate distributor
-gear pump
-check gear pump
-inadequate temperature
-regulate distributor
The engine stalls on touching the -low idle
-wait for temperature to rise
mast -distributor not regulated
-adjust starting point
-gear pump
-joystick not working -change joystick
The mast does not go up or tilt
-no pressure to distributor -change gear pump
-check joystick
-no current reaching electro-valve
The 4th valve is not working -change distributor
-change gear pump
-resolve hydraulic leaks
-leaks in distributor or lines -raise cylinders, close valve and wait
The load is automatically lowered
-faulty lifting cylinder to see if it drops; if it does, cylinders
faulty

Page 67 of 90
E-2.5 Engine

-check battery
-check battery cut-off device
-engine not turning over -check starter motor
-no fuel reaching the pump -emergency stop on
The engine doesn't start
-no fuel reaching the injectors -check fuses
-heaters -key cylinder
-no fuel
-heaters not receiving 12V
-check circuit
-air getting into circuit
-add fuel
-low fuel level
-replace fuel filter
The engine starts with difficulty -fuel filter blocked
-change hoses
-pump error
-change water separator (first hot-
-injectors
wire to check)
-check air filters
-check turbocharger
The engine has no power
-check valve setting
-check fuel filter
-adjust oil level
Oil is coming out of the exhaust -oil level too high
-check turbocharger
-check oil level
-poor fuel quality
Too much smoke is coming out of the -check air filters
-oil level too high
exhaust -check fuel quality
-fuel pump damaged
-check pump
-check fuel level
-check for leaks in lines
The engine cuts out after starting -check filters
-check water separator
-clean turbocharger

Page 68 of 90
Section F
APPENDICES
CONTENTS
F-1 HYDRAULIC DIAGRAM H70 (2WD)
F-5 TIGHTENING TORQUES
F-6 LOAD DIAGRAMS
F-7 MAINTENANCE REPORT TEMPLATES

Page 69 of 90

Page 70 of 90

Page 71 of 90

Page 72 of 90

Page 73 of 90
F-5 TIGHTENING TORQUES

Whenever possible, apply the tightening torque by holding the head of the screw firm and turning the nut. To apply
the right torque (Nm) when tightening the screws, you must first know the following data:
• Screw diameter in mm (metric) or inches (Whitworth)

• Pitch (standard, distance between two consecutive thread crests)
• Quality or grade (class, referring to the strength of the material)
With these values and the help of the following tables, you can find the right torque in Nm:
ZINC-PLATED METRIC SCREWS

Property class Property class Property class Property class
D P 8.8 9.8 10.9 12.9
(mm (mm Tor- Ten- Tor- Ten- Tor- Ten- Tor- Ten-
) ) que sion que sion que sion que sion
(Nm) (N) (Nm) (N) (Nm) (N) (Nm) (N)
4 0.70 2.2 3985 2.5 4484 3.2 5853 3.8 6849
5 0.80 4.3 6514 4.9 7335 6.3 9568 7.4 11196
6 1.00 7.5 9195 8.5 10336 11.0 13506 12.9 15805
8 1.25 18 16863 20 18968 26 24768 31 28984
10 1.50 36 26838 41 30197 52 39418 61 46128
12 1.75 62 39119 70 44022 91 57457 106 67236
14 2.00 99 53707 111 60251 145 78882 170 92309
16 2.00 153 73808 173 83165 225 108406 263 126858
18 2.50 220 92440 - - 313 131897 366 154348
20 2.50 311 119003 - - 440 169385 515 198216
22 2.50 424 148374 - - 602 211534 704 247540
24 3.00 534 171437 - - 758 243914 887 285432

Page 74 of 90
ZINC-PLATED WHITWORTH SCREWS

Grade 2 Grade 5 Grade 8
Measurement
Torque (Nm) Torque (Nm) Torque (Nm)
5/16 10 - 14 16 - 22 24 - 33
3/8 19 - 26 29 - 41 43 - 60
12/125 4-6 7 - 10 11 - 15
14/150 27 - 37 41 - 57 61 - 85
WARNING
IMPORTANT NOTES:
• Never exceed the specified tension value and never continue tightening after the torque spanner reaches
the given torque.
• Torque spanners are precision tools that require special care and treatment.

Page 75 of 90
F-6 LOAD DIAGRAMS
Load diagrams for the MAST EXPLORER rough terrain forklift truck H70/80DA models are shown below. These
forklifts can operate for different centres of gravity from the load to the mast carriage (CDG_Qe en mm) and
different loads (kg).
Qm
CDG_QM
QM
Qi
Qe
Y_Qe
+Y
+X
CDG_Qi CDG_Qm
CDG_Qe Xi X1 Xe
FOR H70DA MODEL:

Mast height 3300 mm
Mast height 4300 mm
Load (kg)
Mast height 6000 mm
CG_Qe (mm)

Page 76 of 90
FOR H80DA MODEL:

Mast height 3300 mm
Mast height 4300 mm
Load (kg)
Mast height 6000 mm
CG_Qe (mm)
F-7 MAINTENANCE REPORT TEMPLATES

Page 77 of 90
50-HOUR MAINTENANCE REPORT

Forklift ID Number:
X Mechanic X Mechanic
Chassis check Brake system
Cracks or splits Pads, drums or calipers
Bumps Seal
Overhead guard Hydraulic installation
Seat Valve block seal
Seat belt Cylinder and tube seal
Data plates Tight connections
Noise Oil level
Clearances Filters
Bearings Articulations and levers
Greases and seal Engine
Transmission Check filters, oil, diesel
Oil level Radiator
Pump Belts
Motor Starter motor
Seal Exhaust pipe and exhaust emission
Wheels and bearings Mast, carriage and forks
Punctures and deformities Clearances
Check wear Rollers and chain
Travel controls Cylinder seal
Accelerator and brakes Wear
Gear stick Greasing
Electrical system Tilt cylinders and accessories
Electrical panel check Cylinder linkage, pins, locks
Wiring condition Runner wear
Safety system Seal
Lights, beacon Tight connections
Horn and acoustic warning alarm Battery
Fuse box Cell condition
Cleanliness and watertightness Jumpers, dirt, cover condition
Steering system Water and electrolyte level
Clearances Check alternator charge
Greasing Others
Seal Check fluids and components
DATE, SIGNATURE AND STAMP

Page 78 of 90
200 AND 500-HOUR MAINTENANCE REPORT

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 79 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 80 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 81 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 82 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 83 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 84 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 85 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 86 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 87 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 88 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 89 of 90

Page 90 of 90

H70 80da en 001

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

H70 80da en 001

Uploaded by

Copyright:

Available Formats

Rough Terrain Forklift Trucks H70/80 DA

Operation and Maintenance Manual H70/80 DA

Operation and Maintenance Manual H70/80 DA

This manual has been written by staff at MECANO

WARNING the model described in this manual.

In this case, contact the MECANO CONTINENTAL

This manual is divided into the following sections:

B) OPERATION AND OPERATING

Section A: general information on the machine and its

Section B: important for machine operators. All the

Section C: important for maintenance staff. This section

Section D: important for all staff: operators,

Section E: its purpose is to diagnose and solve

Section F: additional information such as hydraulic

These sections are in turn sub-divided into sequentially

If you have any trouble understanding this manual, or

Operation and Maintenance Manual H70/80 DA

While operating the forklift, the operator may find

There are five special (or safety) symbols used in the

In some cases the text may be accompanied by

The special (or safety) symbols are shown below in

Operation and Maintenance Manual H70/80 DA

B) OPERATION AND OPERATING

Operation and Maintenance Manual H70/80 DA

SECTION A: GENERAL INFORMATION

A-1.2 Forklift layout .................................................................................................................................................. 13

A-2 FORKLIFT INFORMATION .................................................................................................................................. 14

A-2.2 Model and type. Chassis number .................................................................................................................. 14

A-2.3 Permissible loads per model .......................................................................................................................... 15

A-2.4 Main measurements and specifications ......................................................................................................... 16

A-2.5 Engine specifications ..................................................................................................................................... 17

A-2.6 Fluids .............................................................................................................................................................. 17

A-2.7 Wheels and brakes ........................................................................................................................................ 17

A-2.8 Other data of interest ..................................................................................................................................... 18

A-2.9 Forklift's residual capacity .............................................................................................................................. 18

A-3 PERMITTED USES .............................................................................................................................................. 18

SECTION B: OPERATION AND OPERATING INSTRUCTIONS

B-2.2 Adjusting the seat........................................................................................................................................... 23

B-2.3 Putting on the seat belt .................................................................................................................................. 23

B-2.4 Adjusting the steering wheel .......................................................................................................................... 23

B-2.5 Adjusting the rear-view mirrors ...................................................................................................................... 24

B-3 OPERATOR'S CONTROL PANEL ....................................................................................................................... 24

B-3.2 Instruments and controls ................................................................................................................................ 24

B-3.3 Joystick .......................................................................................................................................................... 26

B-3.4 Hydraulic oil level gauges .............................................................................................................................. 27

B-3.5 Lights panel and hour meter .......................................................................................................................... 27

B-4 ELECTRICAL SYSTEM ........................................................................................................................................ 28

Operation and Maintenance Manual H70/80 DA

B-5.2 Disconnecting the battery .............................................................................................................................. 29

B-5.3 Battery location .............................................................................................................................................. 29

B-5.4 Battery disposal .............................................................................................................................................. 29

B-6 TRANSPORTING THE FORKLIFT ...................................................................................................................... 30

B-6.2 Transporting by crane .................................................................................................................................... 30

B-7 CLEANING AND WASHING THE FORKLIFT ...................................................................................................... 30

C-3.2 Engine identification ....................................................................................................................................... 35

C-3.3 Inspection of the engine alternator ................................................................................................................ 36

C-3.4 Inspection of the alternator belt ..................................................................................................................... 36

C-3.5 Instructions for replacing the belt: .................................................................................................................. 36

C-3.6 Changing the coolant ..................................................................................................................................... 37

C-3.7 Checking the coolant level ............................................................................................................................. 38

C-3.8 Replacing the air filter .................................................................................................................................... 38

C-3.9 Cleaning the air filter ...................................................................................................................................... 39